At RKT, precision mold making is our cornerstone of a seamless injection molding process, delivering consistently exceptional results whether in-house or at the customer’s facility.
Our mold-making expertise ensures maximum precision, process reliability, and performance. Explore the extensive know-how of our mold shop, discover our comprehensive services, and learn how our high standards drive excellence in every project, ensuring consistent, first-class results.
At RKT, our mold making for plastic injection molding covers the entire process chain from initial mold design to the finished mold insert. Every stage of manufacturing is carried out in-house, ensuring full control, transparency, and uncompromised quality throughout the project lifecycle.
Seamless integration of engineering, manufacturing, and validation, provides exceptional process consistency. Our extensive in-house expertise sets us apart, enabling rapid response, efficient design modifications, and optimization at any stage of the injection molding process.
Our engineering department brings extensive experience and technical know-how to every project, whether developing new molds or solving complex challenges of existing tools. The result is precision-engineered molds designed and built for superior performance, durability, and long-term production stability.
Long-term experience from injection molding production is valuable for mold making, for example, to solve layouts differently in follow-up projects or to receive feedback for improvements from the injection molding process. When molds are used in continuous operation, experience regarding steels can be gathered: What is the service life of the steels? Which coatings should ideally be used? Is the selected venting adequate?
With supplied molds, problems with corrosion have previously occurred during production. The problem here lay in the selection of the steel quality: Hot-work steels with a low chromium content were used, which favored corrosion. Our molds show no corrosion because we ensure a sufficiently high chromium content in the steel.
When we receive new product ideas where initial prototypes exist and the step into industrial series production is to be taken, we closely support the implementation in plastic. To create a suitable injection molding tool, our experts examine:
Because mold design and manufacturing represent a significant long term investment, every injection molding parameter is thoroughly analyzed, optimized, and validated to provide consistent, precise, and reliable component quality.
Our team is ready to help you bring your product idea to market with confidence, turning innovative concepts into proven plastic injection molding solutions. Contact us:
Stefan Preis
Head of Project Business
S.Preis@rkt.de
Our precision mold-making expertise extends to the most demanding micro-scale applications. Utilizing an extensive range of advanced in-house manufacturing technologies, we produce ultra-precise, finely structured molds capable of replicating even the most complex microstructures with feature sizes in the micrometer (µm) range.
Our technical expertise ensures the reliable production of high-precision micro components with exceptional surface quality, extremely tight dimensional tolerances, and outstanding performance even for the most complex geometries. Our vertically integrated in-house expertise ensures maximum flexibility and rapid response. Project Example: A customer transferred a mold to us for correction. Issues quickly became apparent during our initial run-off. Improper cylindrical grinding of delicate cores resulted in unacceptable process instability and inconsistent part quality.
Leveraging our in-house diagnostic and machining capabilities, we were able to quickly identify the root cause and implement corrective actions. The mold was reworked in-house, re-machining the cores with high-precision cylindrical grinding to restore geometric accuracy and dimensional stability, avoiding costly delays.
A core strength of RKT is our in-house ability to machine, adapt, and optimize mold bases whenever engineering changes or performance improvements are needed. By eliminating reliance on external suppliers, we can implement real-time adjustments quickly, ensuring faster turnaround, greater flexibility, and uninterrupted production performance.
Manufacturing multiple components in one mold and one shot succeeds with high-cavitation molds, which are in demand for series productions with high quantities. Molds with at least eight identical mold inserts are referred to as high-cavitation; higher numbers, such as 16, 32, or 64 and up to 128 cavities, are also common in our production.
The layout and manufacturing of high-cavitation molds require high precision so that all steel inserts turn out absolutely identical in form and surface quality, in order to achieve components of equal quality with the same dimensions and tight tolerances.
Read more about the use of high-cavitation molds.
During the validation phase, every mold, whether customer-supplied or manufactured by us, undergoes comprehensive testing in real production conditions. Our standard validation process is conducted in accordance with ISO 13485, including: Design Qualification (DQ), Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ)
Validation to PPAP (Production Part Approval Process) and other customer-specific standards is carried out as required as well. Depending on project requirements, we also perform: DoE (Design of Experiments), Pro-Op (systematic, step-by-step process optimization), Filling and flow studies.
Mold inserts for micro components, such as those used in microfluidic applications, are inspected and validated using high-precision confocal microscopes able to detect even the smallest deviations in surface topography.
Further analytical capabilities include: CT scans, Polariscope analyses.
RKT’s structured and comprehensive validation approach ensures maximum process stability, regulatory compliance, and long-term production reliability.
