Automotive · Door Module Plastic Injection Molding Mold Insulation

16% faster cycles in 2 workshop days. No PPAP. No tooling changes.

−16%Cycle time

−18.3%Hot runner temp

2 daysWorkshop

The challenge

Door module, Tier 2 in Chicago. Tier 1 sponsored. Target: 16% savings.

A door-module supplier running an older 610-ton Toshiba hydraulic press, panel-design tool. The Tier 1 sponsored the workshop with a target of 16% supplier savings — without ANY tooling modifications, ANY material change, or ANY PPAP requalification.

The workshop

2 days. Disassemble manifold, install insulation, step temperature down, measure.

DAY 1 · STEP 1

Disassemble manifold

Pull the manifold out of the tool to prepare for mold insulation. Quarantine the mold area. Document baseline temps and cycle.

DAY 1 · STEP 2

Install military-grade insulation

Apply thermal barrier between manifold and tool. Wrap key zones. Validate fit. No tooling modifications required.

DAY 1 · STEP 3

Reassemble & warm up

Reinstall manifold. Bring the press up to baseline temperature. Press is ready for the Day 2 optimization run.

DAY 2 · STEP-DOWN TEMPERATURE REDUCTION

Hot runner temp dropped 6 steps from 465°F to 380°F.

The press was running 85°F hotter than melt temp before insulation. After insulation, we stepped the temperature down progressively, verifying part quality at each step. Cool time dropped from 19.4s to 13.3s.

465°F → 440°F → 420°F → 410°F → 400°F → 390°F → 380°F FINAL

The outcome

Result.

16% cycle time reduction (32.4s → 27.4s). 18.3% temperature drop. Part quality verified by the supplier’s quality team — visually and dimensionally — vs. the pre-insulation parts. Process and parts approved for production. No PPAP. No tooling change. Zero capital required.