Why Complex Plastic Structures Increase Mould Costs

During the research and design of plastic products, designers often create complicated mold structures to make products look better or have more functions. However, they usually ignore the mold development costs.

A complex plastic structure will raise mold expenses greatly in many aspects, including mold design, mechanical processing, accessory installation, mold quantity, mold testing and modification, and long-term production risks.

The specific reasons why complex structures lead to higher mold costs are as follows:

1. Complex structures require multiple molds and raise  mold costs

Complex plastic parts cannot be formed in one single mold due to limitations of molding techniques, demolding rules and structural conflicts. They need multiple sets of molds for separate injection molding and secondary processing. In comparison, most simple plastic products only need one basic two-plate or three-plate mold to complete production.

2. Additional professional mold mechanisms raise material and accessory costs

The structure of plastic parts decides the design of their molds. If products have complex shapes such as internal and external undercuts, side holes, special-shaped grooves and irregular concave and convex surfaces, the molds cannot open and close to release products normally.so we also need high-quality premium mold steel to meet product performance，which further increases mold manufacturing costs.

3.Higher design and processing difficulty increases labor and equipment costs

For simple plastic products, their molds adopt standardized and clear structures. Designers can finish modeling, mold splitting and drawing quickly with less working time and difficulty.

For complex structures,、Designers need to spend several times longer on solution design, simulation checking and structural optimization to avoid molding interference,which greatly increases design time and labor costs.

In the processing stage,simple molds only need basic procedures such as CNC milling, polishing and drilling. Complex molds require repeated precision processing with high-end equipment like wire cutters, mirror spark machines and precision grinders.

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