A military-grade mold-insulation breakthrough — 5 years of partnership with STS, 100+ installations, zero failures, ROI under 6 months. Applied to PC, ABS, PA, PP, HDPE, TPO, TPE, TPU across 300–4,500 ton machines.
More parts per hour from the same press, same tool.
Lower mold temp → less energy → fewer emissions per part.
Direct passthrough to your unit economics — shared savings model.
Fast payback. No retooling capital. No PPAP requalification.
Without a thermal barrier between manifold and tool, your mold develops cold spots — and the press compensates by running 70°F hotter than melt temperature. That extra heat stays trapped in the part and tool, extending cooling time and burning energy.
Engineers have known the problem for decades. Asbestos was the original approach — banned for being carcinogenic. Ceramic boards came next — too rigid, not durable, impractical at scale. Then nothing for 30 years.
Survives 2000°F. Lasts the life of the tool. Enables fast changeovers. CSC partnered with STS to bring it to industrial manufacturing.
A thermal barrier between the manifold and the tool lets the mold run cooler and more evenly — so there's far less heat to remove on every shot, and cooling (50–70% of the cycle) drops sharply.
Thermal barrier eliminates cold spots so the entire mold runs at a consistent, lower temperature. Done on-press during a normal changeover.
Less heat to put in. Ejection temperature stays at 200°F (unchanged) — but there's less heat in the part and tool to remove.
~20% faster cycle, ~20% less energy, ~20% less CO₂. Part quality unchanged. No PPAP. No tooling changes.
The insulation sits directly under the hot-runner manifold, blocking heat from soaking into the tool steel. The mold runs cooler and more evenly — so there's less heat to pull back out on every shot. It survives 2000°F, lasts the life of the tool, and installs during a normal changeover: no PPAP, no tooling changes.
Automotive door module at a Tier 2 supplier in the Chicago area. Tier 1 sponsored the work; CSC ran the workshop on a 610-ton hydraulic Toshiba press with the panel-design tool.
Temperature stepped down progressively across both workshop days: 465 → 440 → 420 → 410 → 400 → 390 → 380 final. Cool time alone fell from 19.4s to 13.3s.
1100-ton hydraulic press, natural-gas powered facility, 620,540 units/year. After mold insulation: faster cycles, more parts per hour, dramatic CO₂ reduction over the model's run.
Excluded: thermosets.
Bigger machines, larger parts, more volume — all amplify the savings.
Pick 2–3 parts. Prove the technology and capture the financial + capacity benefit. Internal: plant + ops + tooling eng. Supply base: buyers + tooling eng.
Each plant manager identifies high-impact parts. Business cases developed, technical feasibility confirmed, 2026 savings budgets estimated.
Global lead PM identified. Timelines, savings tracking, budgets in place. Projects launched and tracked across plants.
Tooling specs updated to include mold insulation and 10mm tolerancing. Future product costed at the lower structure — wins new business.
| Applicable spend | Low (5%) | Mid (8%) | High (12%) |
|---|---|---|---|
| $10M | $500,000 | $800,000 | $1,200,000 |
| $20M | $1,000,000 | $1,600,000 | $2,400,000 |
| $30M | $1,500,000 | $2,400,000 | $3,600,000 |
Real-world average is ~8% to sell price across the network. CSC is paid only from the verified savings — no upfront fee.
