ISO 9001:2015 Certified
Standardized Quality Management
- +86-173 9807 5880
- quote@rallyplastic.com
Precision In-House Tooling Dedicated to Your Custom Plastic Parts. Shorten lead times, reduce part costs, and ensure reliable mass production quality.
ISO 9001:2015
Certified
Strict NDA
Compliance
RoHS & REACH
Compliant
10+ Years
Injection Molding Experience
A look inside our tooling capabilities. From intricate core and cavity details to robust multi-cavity structures, explore the high-precision steel molds we build in-house.
We engineer the exact tooling required for your project’s volume, budget, and complexity.
Designed for high-volume production (100,000+ parts). Rally Plastic engineers and machines hardened steel molds with up to 128 cavities. Our tooling experts focus on perfectly balanced hot/cold runner systems, optimized conformal cooling channels, and extreme machining tolerances (+/- 0.01mm) to ensure identical dimensions across every single cavity while maximizing mold life.
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When you need to validate your design with real injection-molded parts fast (typically 100 to 10,000 units), we build rapid molds using softer P20 steel. By utilizing standardized mold bases and fast-tracking the core/cavity CNC machining, we can complete these bridge tools in as little as 3 to 7 days, saving you significant upfront tooling costs.
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Building a 2K mold requires exceptional engineering to manage complex core back movements or rotary platen mechanisms. We manufacture high-precision two-shot tooling with perfect shut-offs, ensuring two different materials or colors bond flawlessly without flash. Our meticulous mold design guarantees precise tool alignment, saving you secondary assembly costs while achieving a premium finish.
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To encapsulate custom metal components (like threaded brass inserts or stamped brackets), Rally Plastic can design molds with specialized locating pins, slides, or magnetic mechanisms to hold the inserts securely against high injection pressures. Our tight-tolerance mold machining ensures zero flashing around the metal parts and prevents any crushing or displacement of the inserts during production.
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Strictly for low-volume production runs (10 to 1000 parts). Instead of cutting metal, Rally Plastic creates highly accurate silicone molds from a master pattern (usually CNC machined or SLA 3D printed). This soft-tooling approach for vacuum casting allows us to deliver complex, production-like plastic parts in just 10 to 15 days.
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By keeping the entire mold-making and injection molding process under one roof, we eliminate the risks of dealing with fragmented supply chains, saving you time.
Avoid tooling transfer headaches in China. Designing and running your custom plastic mold under one roof prevents miscommunication and delays.
Enjoy free lifetime mold maintenance for injection molding. We guarantee your tooling lifespan as long as we manufacture your parts.
Experience a streamlined injection mold manufacturing process. We transition instantly from T1 sample approval to mass-producing your custom parts.
Our custom mold manufacturing services are powered by a climate-controlled tooling workshop. Rally Plastic guarantees that every core and cavity is cut with uncompromising precision.
Equipped with advanced 5-axis and 3-axis CNC machines operating at ultra-high spindle speeds up to 24,000 RPM.
Rally Plastic utilizes high-end EDM machines for processing complex geometries that standard end-mills cannot reach.
Specialized deep-hole drilling equipment capable of gun-drilling complex cooling channels up to 800mm deep within the steel blocks.
Rally Plastic manufactures injection molds perfectly matched to our 80T - 800T injection presses. Please refer to the table below for our standard supported mold sizes; if you have specific requirements, please contact our engineers.
| Mold Category | Cavitation | Part Weight Range | Max Part Dimensions | Compatible Injection Tonnage |
|---|---|---|---|---|
| Micro Molds | 4 to 128 Cavities | 0.1g – 15g | 1×1×1 mm – 50×50×30 mm | 80T – 120T |
| Small Molds | 2 to 32 Cavities | 15g – 200g | 50×50×30 mm – 200×150×100 mm | 120T – 250T |
| Medium Molds | 1 to 8 Cavities | 200g – 800g | 200×150×100 mm – 450×350×200 mm | 250T – 500T |
| Large Molds | 1 to 2 Cavities | 800g – 4,500g | 450×350×200 mm – 1,000×800×500 mm | 500T – 800T |
| Prototype / Rapid Molds | 1 to 2 Cavities | Varies by design | 10×10×5 mm – 1,000×800×500 mm | 80T – 800T |
Rally Plastic sources 100% genuine tool steel from certified suppliers. We match the exact steel grade to your part's material and production volume.
Rally Plastic leverages P20's excellent pre-hardened machinability to mill your mold rapidly, saving you up to 20% in upfront tooling time and costs without the need for thermal treatment.
By utilizing 718H's superior uniform hardness (HRC 33-38), Rally Plastic ensures a denser core strength and a much cleaner SPI-B surface finish than standard P20 can achieve.
Rally Plastic vacuum-quenches genuine H13 steel to HRC 48-52, providing extreme thermal fatigue resistance so your mold won't crack even when injecting high-temperature, highly abrasive resins.
NAK80 can easily achieve flawless SPI A-1 mirror polishes and highly precise Mold-Tech textures without the dimensional risks of post-heat treatment.
The surface finish dictates your part's final look, feel, and mold release efficiency. At Rally Plastic, we execute strict SPI standards and custom textures to ensure your product matches your exact aesthetic requirements.
Achieves a flawless, mirror-like finish using fine diamond buffing. Rally Plastic applies this polishing process to premium cosmetic surfaces.
Typical Applications: Medical Lenses, Clear Displays, High-End Cosmetic Packaging.
A highly cost-effective choice that removes all CNC machining marks, leaving a clean, medium-gloss surface.
Typical Applications: Home Appliance Housings, Consumer Electronics, Medical Equipment Covers.
Leaves a smooth but dull, matte appearance. Rally Plastic recommends this budget-friendly option for internal structural parts.
Typical Applications: Internal Brackets, Industrial Enclosures, Hidden Automotive Chassis.
Standardized Quality Management
Eco-Friendly & Safe Polymers
Verified China Factory
Your IP & CAD Drawings are Safe
Certified Engineering Plastics
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Rally Plastic utilizes advanced metrology equipment and meticulous inspection processes at every stage of mold manufacturing, providing you with genuine precision molds.
Before cutting begins, our quality team rigorously inspects all incoming raw steel blocks and custom graphite electrodes. Using advanced material spectrometers and micro-calipers, Rally Plastic verifies the material composition, hardness levels, and block dimensions to ensure they strictly meet your certified engineering specifications from day one.
Once the steel core and cavities are machined, they undergo high-precision inspection using our state-of-the-art Coordinate Measuring Machines (CMM). Our quality inspectors scan complex 3D profiles and tight-tolerance shut-off surfaces down to ±0.005mm, guaranteeing absolute dimensional accuracy and zero flash during injection.
During the initial T1 trial, Rally Plastic extracts sample plastic parts and perform a comprehensive First Article Inspection (FAI). We compare every critical dimension directly against your original CAD model, ensuring the mold is fully optimized and ready to deliver flawless mass production parts.
Before any steel is cut, your 3D CAD models undergo a rigorous, free DFM engineering and mold flow analysis by Rally Plastic’s senior tooling team.
01
Rally Plastic simulates how molten resin flows inside the mold before cutting steel. Strategic gate positioning prevents air traps, weld lines, and short shots.
02
We optimize mold parting lines and surface tapers so your custom parts eject smoothly without drag marks, scratches, or pin push-through during demolding.
03
Balanced wall thickness in your mold design prevents part warpage, volumetric shrinkage, sink marks, and internal voids during high-pressure injection.
04
We fine-tune structural ratios and fillet radii in the tooling design to maximize mechanical strength while keeping exterior cosmetic surfaces visually flawless.
Different industries demand different tooling strategies. We don't just cut steel; we engineer custom molds optimized for your industry's specific resin requirements, cosmetic standards, and dimensional tolerances.
Consumer electronics require flawless cosmetics and precise snap-fit assemblies. We specialize in building thin-wall molds and utilizing high-precision EDM (Electrical Discharge Machining) to create micro-features. Our tooling experts expertly handle high-polish SPI A-1 finishes and complex Mold-Tech textures, ensuring your enclosures and device housings look premium right out of the mold.
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Automotive components often use engineering-grade, glass-fiber-reinforced resins (like PA66+GF) that are highly abrasive to steel. We build heavy-duty molds using premium hardened tool steels (like H13 or customized alloys) to guarantee extended tool life. Our designs incorporate sophisticated slide mechanisms and lifters to handle undercuts, and optimized hot runner systems for large structural or under-the-hood parts.
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Industrial parts demand maximum strength and durability, often involving thick-walled designs. Our mold engineering focuses on advanced conformal cooling channels to prevent sink marks, warpage, and internal voids during cooling. We also heavily design robust insert molds to securely hold heavy metal hardware and threaded inserts essential for industrial machinery.
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There is zero margin for error in medical tooling. We build molds with extremely tight shut-offs to guarantee flash-free parts, which is critical for medical disposables and housings. We utilize highly polished, corrosion-resistant stainless steel (like S136) to maintain pristine mold surfaces, ensuring clean release and perfect clarity for transparent medical grade plastics.
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Because your mold stays at Rally Plastic for mass production, we provide 100% transparent data to give you complete peace of mind from afar. You receive clear proof of steel quality, dimensional accuracy, and process stability before we start manufacturing.
A direct comparison between the first molded samples and your CAD, proving we hit your strict tolerances.
Authentic proof that we used genuine tool steel (like ASSAB or LKM) to guarantee your mold's lifespan.
Hardness test results proving the steel was properly treated to survive thousands of injection cycles.
The exact temperatures, speeds, and pressures our engineers established during testing.
Find answers about tooling ownership, mold maintenance, lead times, design modifications, IP protection, and quality guarantees.
Injection molding facilities require specialized, heavy-duty ventilation systems to manage thermal loads and maintain indoor air quality. Because thermal plasticizing and cooling towers generate significant ambient heat, facilities utilize massive roof exhaust fans and high-volume industrial air exchanges. Furthermore, localized exhaust hoods are positioned directly above injection presses to safely extract volatile organic compounds and polymer fumes. Rally Plastic maintains a rigorously controlled, well-ventilated workshop environment to protect technicians and ensure stable processing conditions.
Achieving strict dimensional accuracy in miniature injection molding demands extreme mechanical precision and specialized micro-machining capabilities. Manufacturers utilize micro-EDM and high-precision CNC equipment to cut intricate cavity features down to micron-level tolerances. Maintaining this accuracy also requires micro-injection presses with ultra-sensitive screw control and closed-loop hydraulic monitoring. Rally Plastic leverages these advanced techniques to eliminate flash, preventing micro-part distortion. Consequently, Rally Plastic consistently delivers high-tolerance miniature components that meet exact engineering specifications.
Manufacturing high-durability injection molds requires a meticulous multi-stage engineering sequence. The workflow begins with software-driven DFM analysis, followed by high-speed CNC machining and precision wire EDM to carve the core and cavity blocks. Specialized heat treatment processes then harden the tool steel to withstand millions of high-pressure cycles. Rally Plastic executes this entire tooling process in-house, ensuring absolute structural integrity. Every mold built by Rally Plastic is rigorously tested via CMM inspection before mass manufacturing.
We process premium engineering plastics including ABS, PC, PP, PA, etc. equipped with injection molding machines ranging from 100 to 800 tons.
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