Plastic part DFM
Wall thickness, draft, ribs, bosses, undercuts, shutoffs, shrinkage, appearance zones, gate options and ejection feasibility reviewed against the selected material and production intent.
For OEMs, tool makers and plastics manufacturers
Injection Mould & Plastic Part Design
Plastic part DFM, injection mould design, mould flow analysis and controlled tool documentation developed as one connected engineering package.
Fabrixon at a glance
Fabrixon’s Achievements
Specialist mould engineering supported by broader mechanical design capability, controlled documentation and experience across product and industrial programmes.
Talk to an Engineer150+Projects delivered
25+Active clients
50+Years combined experience
25+Years specialist mould design
Mould engineering scope
From plastic partto controlled toolhandover.
We structure the programme around mouldability, production volume, tool architecture, process behaviour and the information your tool maker needs before steel is committed.
Mould concept & architecture
Cavity count, parting strategy, gates, runners, slides, lifters, ejection, cooling, mould base and machine interfaces developed as one coordinated tool concept.
Mould flow & design validation
Fill, pack, cooling and warpage studies applied where they add decision value, with findings fed back into gate, runner, cooling and part geometry decisions.
Detailed mould design
Controlled cavity, core, insert, slide, lifter, ejection, cooling, venting and standard component geometry developed around the agreed tool maker and manufacturing route.
Tool documentation & handover
Native CAD, component drawings, BOMs, steel and finish requirements, exchange files, simulation evidence and revision records issued through agreed review gates.
Ways to work
Three ways to work with Fabrixon.
Engage Fabrixon for a complete part and tool programme, recurring specialist capacity, or a defined mould engineering package inside an existing programme.
01Complete programme
Part and mould design projects
Plastic part engineering, DFM, mould architecture, detailed tool design, defined simulation studies and controlled documentation delivered through one project structure.
Discuss a mould programme02Recurring capacity
Dedicated Mould Engineering Support
Recurring specialist capacity for tool makers, moulders and product teams managing variants, design changes, drawing backlogs and multiple tooling programmes.
Discuss dedicated capacity03Specific scope
Defined mould engineering scopes
DFM review, mould concept, cavity and core design, cooling, mould flow analysis, documentation or correction of an existing tool design.
Discuss a defined scopePart and tool applications
Plastic Parts and
Mould Configurations
We Engineer
The engineering route is defined around part geometry, resin, production volume, tool life and moulding process rather than applying one generic mould architecture.
Consumer Products and Enclosures
Housings, covers, handles and visible components where appearance, texture, parting conditions and assembly interfaces shape the tool.
Industrial and Technical Plastic Parts
Functional enclosures, brackets, guards and machinery components requiring controlled geometry, material performance and repeatable assembly.
Automotive and Transport Components
Interior, exterior and technical plastic parts developed around customer surface, dimensional, material and documentation requirements.
Packaging, Caps and Closures
High volume components where cavity count, runner balance, cooling, repeatability and cycle objectives are commercially important.
Multi Cavity, Family and MUD Tooling
Balanced multi cavity or family tools plus interchangeable insert strategies where common frame economics and variant flexibility matter.
Insert Moulding, Overmoulding and Complex Actions
Parts using inserts, multiple materials, slides, lifters or coordinated tool actions requiring integrated part, process and tooling decisions.
Advanced mould engineering
Advanced Tooling
Design and Integration
Where geometry, cycle performance, maintenance or programme economics justify more than a conventional tool arrangement, specialist features are developed as part of the mould architecture.
Thermal performance
Conformal Cooling and Additive Inserts
Cooling passages following cavity geometry where conventional drilling cannot provide the required thermal control, applied where dimensional stability or cycle performance justifies the added complexity.
Complex tool motion
Sequential Release and Complex Actions
Slides, lifters, latch systems and hydraulic or pneumatic core pulls coordinated around the required release sequence, movement clearance and ejection strategy.
Production architecture
Hot Runner and Multi Cavity Integration
Feed system, cavity, cooling and ejection architecture coordinated with selected hot runner and standard component suppliers for repeatable high volume production.
Selected engineering evidence
Mould engineering in practice.
Examples showing how tool architecture, simulation and controlled design decisions are applied to production mould programmes and complex tooling mechanisms.
Mould Design Engineering
Sequential Release Mechanism Mould
Production mould design using sequenced release mechanisms and CATIA motion verification to eliminate demoulding warpage.
View case study
Mould Design Engineering
Conformal Cooling Production Mould
Production injection mould engineering for a thick wall PA6+GF30 component using selective conformal cooling, balanced filling and Moldflow led warpage control.
View case study
Mould Design Engineering
Large Tonnage Automotive Exterior Panel Mould
Large scale injection mould engineering for matched automotive exterior panels with zoned cooling, controlled filling, ejection and mould base structural validation.
View case studyWhy manufacturers outsource mould engineering
Add specialist mould engineering capacity without expanding permanent headcount.
Outsourcing is most valuable when specialist tooling work, unresolved mouldability or programme peaks begin to delay quotations, tool release or production timing.
Specialist tooling capacity
Access experienced mould design capability for cavity/core, slides, lifters, cooling, ejection and detailed documentation without recruiting for intermittent programme demand.
Part and tool decisions stay connected
DFM findings, gate strategy, ejection, cooling and tool actions are coordinated rather than passed between separate part and tooling workstreams.
Simulation before steel is committed
Flow, cooling and warpage studies can inform practical design choices while the part and tool architecture can still be changed economically.
Tool maker ready handover
CAD, drawings, BOMs, technical specifications, analysis evidence and revision records are consolidated into a controlled package for review and manufacture.
Engineering handover
A controlled package your team and tool maker can work from.
Part intent, mould architecture, simulation evidence, tool documentation and revision status stay connected through the agreed review and release process.
V5
MoldflowNative + neutral CAD · controlled tool drawings · simulation evidence · BOMs · tool maker files · revision status
PART
Plastic Part and DFM Package
Review findings, marked models, recommended geometry changes and the agreed mouldability basis for material, appearance and critical features.
MOULD
Complete Mould CAD Assembly
Cavity, core, inserts, slides, lifters, ejection, cooling, runners, vents and selected standard components within the agreed design scope.
DRAWINGS
Controlled Tool Drawings
Assembly and component drawings covering interfaces, dimensions, tolerances, finishes, steel conditions and revision status.
ANALYSIS
Simulation and Design Evidence
Defined fill, pack, cooling or warpage results with assumptions, findings, limitations and recommended design actions.
BOM
BOM and Technical Specifications
Mould base, standard components, steel and hardness requirements, hot runner information and surface finish references where applicable.
HANDOVER
Tool Maker Exchange Files
Native CAD, STEP, DXF where required, controlled drawing register, review comments and the final issue package.
Buyer questions
Injection Mould Design FAQ
Direct answers to the technical and commercial questions manufacturers ask before outsourcing plastic part and mould engineering.
Can Fabrixon design both the plastic part and the injection mould?
Yes. Fabrixon can develop the plastic part and mould within one coordinated programme, or work from an existing part design. Scope can include DFM, part geometry, mould architecture, simulation and controlled tool documentation.
Can you review an existing plastic part before mould design begins?
Yes. A standalone mouldability and DFM review can assess draft, wall thickness, ribs, bosses, undercuts, shutoffs, gate options, ejection and other features against the selected material and production requirements.
What information is required to quote an injection mould design project?
The most useful inputs are part CAD, drawings, resin, annual and lifetime volume, cavity count if known, cosmetic and critical dimensional requirements, target cycle time, moulding machine information, tool maker preferences and required timing.
Can Fabrixon work with our nominated tool maker and moulding machine?
Yes. The mould architecture can be developed around the nominated tool maker, mould base preferences, standard components, machining and EDM capability, hot runner supplier and moulding machine limits, with review points built into the programme.
What mould flow analysis can be included before tool manufacture?
The analysis route is selected around the design decision. Studies can compare filling pattern, pressure demand, weld lines, air traps, gate position, runner balance, cooling performance, shrinkage and warpage where the available data supports those questions.
Can you design conformal cooling channels?
Yes, where conformal cooling is technically and commercially justified. Cooling geometry can be developed around the cavity and assessed against thermal balance, dimensional stability and cycle performance objectives.
What CAD files, drawings and specifications will our tool maker receive?
The handover is defined by scope and can include native mould assemblies, part and insert models, assembly and component drawings, BOMs, steel and hardness requirements, finish notes, STEP/DXF files, analysis reports and a revision controlled drawing register.
How long does injection mould design take and how is cost estimated?
Timing depends on part complexity, cavity count, tool actions, hot runner integration, analysis scope, documentation depth and review cycles. Fabrixon confirms milestones, assumptions, timing and price in the written proposal before engineering begins.
Start with the engineering brief
Discuss your plastic part or mould programme.
Share what you are designing and the engineering support you need. Part CAD, drawings and production information can be added now or discussed after we review your enquiry.
Complete or defined scopeChoose the right entry route
Engineer led reviewTechnical fit before proposal
Controlled handoverFiles and revision status visible
Send a short engineering brief
Start with the essentials. Add a short note or files if they are available.