Manufacturing Process

Our Workflow

Step-by-Step Process

Every die and mould we manufacture follows a rigorous, proven process to ensure precision, quality, and on-time delivery.

01

Design & Engineering

Customer requirements analysis, 3D modelling in SolidWorks, core/cavity extraction, waterline design, and mould detailing.

02

Raw Material Inspection

Incoming material verification — grade, hardness, dimensions, and certification check before any machining begins.

03

CNC Machining

Precision CNC milling, turning, drilling, and EDM operations on YAMARA & STM machines with tight dimensional control.

04

Assembly & Fitting

Expert assembly of all mould components — inserts, ejector systems, cooling circuits, and guide elements with precision fitting.

05

Testing & Delivery

Mould trial, acceptance inspection, dimensional verification, and final delivery with complete documentation.

Step 1: Design & Engineering

Our design team uses SolidWorks and ToolMaker software to create detailed 3D models based on customer inputs. We carry out mould detailing including 3D surface modelling, wire frame design, 2D drafting, draft analysis, core/cavity extraction, electrode design, and waterline optimization.

SolidWorks ToolMaker 3D Modelling FEA Analysis

Step 2: CNC Machining

Precision machining is performed on our YAMARA (960×500×500mm) and STM (1000×650×600mm) CNC Milling machines, CNC Lathe, ZNC EDM, and CNC EDM. Each operation is programmed with CAM software and verified against the design model for dimensional accuracy.

CNC Milling CNC Turning ZNC EDM CNC EDM

Step 3: Assembly & Quality Inspection

All mould components are assembled by skilled fitters. Quality inspection covers mould intensity, mould-flow analysis, ejection system, spare parts specifications, mould installation check, and mould testing acceptance inspection. We ensure every product meets stringent quality standards before dispatch.

Assembly Mould Flow Analysis Dimensional Check Trial & Testing

Our Equipment

Machinery & Technology

CNC Milling – YAMARA

960 × 500 × 500 mm Travel

High-speed CNC milling for complex 3D profiles, pockets, and contours in die steel and aluminium.

CNC Milling – STM

1000 × 650 × 600 mm Travel

Larger capacity milling for big mould bases and die components with superior surface finish quality.

CNC Lathe

Precision Turning Centre

CNC turning for round components, inserts, and precision parts with excellent concentricity.

ZNC EDM

Spark Erosion Machine

ZNC EDM for intricate cavity profiles and hardened steel — achieves complex shapes impossible by conventional cutting.

CNC EDM

CNC-Controlled EDM

CNC EDM for precise electrode machining and complex cavity work with automated control for consistency.

Drilling Machines

Multi-Spindle Drilling

Precision drilling for cooling channels, ejector holes, and fastener holes in dies and moulds.

Value-Added Service

Re-Engineering Services

We undertake the re-engineering of existing engineering components and systems. Our approach involves modifying existing designs by changing materials based on application requirements — after a detailed FEA (Finite Element Analysis) process — which can drastically reduce product costs.

For example, converting sheet metal and aluminium castings to plastic components reduces cost while adding value through improved aesthetics and design. Our Design Team and Analysis Team provide optimized design solutions considering static and dynamic loading with displacement, stress, and natural frequency constraints.

FEA Analysis

Finite Element Analysis for stress, displacement, and frequency optimization

Material Substitution

Converting metal components to plastic for cost reduction and weight savings

Design Optimization

Shape and mass optimization with respect to performance constraints

Cost Reduction Through Re-Engineering