Custom Chevy C6 Mold Design for Automotive Connector Housing

This production tool design is engineered for a 2-cavity automotive connector housing(Chevy C6).The tool layout is optimized for high-volume injection molding utilizing highly abrasive talc-filled resin.It features multi-axis internal undercut release mechanisms and sequenced demolding to ensure tight tolerance control and reliable part ejection.

 | Technical Specifications

 | Tool Design&Mechanical Features

Hardened H13 Steel Inserts(HRC 50-52)

The specified molding resin,WPP PPH6TF2 Natural2,contains a high percentage of talc filler which causes rapid abrasive wear on standard tooling steel.To handle this,the core and cavity inserts are machined from premium H13 tool steel and through-hardened to HRC 50-52.This configuration minimizes gating wear,prevents flash,and ensures a tool life exceeding 500,000 cycles.

Cavity&Core Side Inner Angle Sliders

Due to the complex internal clips and lateral snap-fits of the Chevy C6 housing,the mold layout integrates inner angle sliders on both the cavity and core sides.These mechanical sliders release internal undercuts during the mold-opening sequence without requiring complex hydraulic core pulls,maintaining high cycle efficiency.

Two-Stage Ejection System

To prevent part deformation or stress marks on deep structural ribs during demolding,a mechanical second ejector system is built into the tool.The primary ejection stage clears the internal undercuts and frees the part from deep core features,while the secondary stage completes the part stripping action safely.

MISUMI Standard Component Integration

All wear components—including leader pins,guide bushings,ejector pins,and slider wear plates—follow MISUMI standard specifications.This precise standardization guarantees component interchangeability and simplifies spare parts sourcing for overseas production facilities.

 | F&Q

Q:Why use H13 steel at HRC 50-52 for this project?

A:The talc filler in WPP PPH6TF2 resin is highly abrasive.Untreated or pre-hardened steels wear down quickly under these conditions,leading to parting line flash.Hardened H13 steel provides the necessary wear resistance and fatigue strength for high-speed automotive production runs.

Q:What is the benefit of using inner angle sliders on both sides?

A:It allows the mold to release complex,interlocking internal undercuts on both the stationary(cavity)and moving(core)halves of the tool.This mechanical solution eliminates the need for expensive external hydraulic cylinders,keeping the tool compact and fast.

Q:How does the second ejector system protect the part?

A:The Chevy C6 housing has deep,thin-walled sections.A single-stage ejection might push the pins straight through or warp the part.The two-stage system splits the ejection stroke into two synchronized movements,ensuring the part is completely free from the steel before being pushed off the tool.

Q:Why is MISUMI standard specified?

A:It ensures that all high-wear tooling components meet tight international tolerances and can be replaced immediately anywhere in the world by ordering straight from the MISUMI catalog code,minimizing factory downtime.