V Solutions Global (VSG) was engaged by a U.S. client to design a complex injection mold for an automotive door trim panel under a compressed launch timeline. The challenge involved managing intricate large-part geometry that required a multi-cavity mold meeting strict OEM standards for surface finish, dimensional accuracy, and durability in high-volume production, all while coordinating tightly across multiple internal teams to hit an accelerated delivery schedule. VSG’s integrated tooling team delivered an end-to-end solution, creating a detailed 3D CAD mold with optimized cooling channels and runner systems validated through Moldflow analysis, while also generating and simulating CNC machining programs and providing complete toolpath documentation to reduce the client’s setup burden. Steel selection was also optimized to extend tool life and minimize maintenance intervals. The results of the engagement were a 29% reduction in lead time, a 75% reduction in scrap rate, and a 50% improvement in tool life.
Tooling & Mold Design
