Episode 289: Adrian is joined again by our head of New Product Development, Paul Adams, to explore the complexity of plastic injection mold tooling and what it takes to go from tooling design to mass production of plastic parts. They explore the full journey, from DFM and tool design through trial runs (T0, T1, T2) to final sign-off and mass production. Along the way, they highlight common pitfalls, golden samples, and why rushing into production can be a costly mistake.
You'll love this episode if you’re developing plastic products, as it will help you to avoid surprises and manage expectations in the new product introduction (NPI) process.
Episode Sections:
-
(00:00:03) Introduction to episode 289
-
(00:00:13) Adrian welcomes back Paul Adams
-
(00:00:35) Today’s topic: plastic injection mold tooling and its complexity
-
(00:01:11) From DFM to mass production – the journey explained
-
(00:02:01) Why tooling is expensive and misunderstood
-
(00:02:48) The role of DFM (Design for Manufacturing) in tooling
-
(00:05:13) Customer involvement and asking the right questions
-
(00:05:19) Tooling design: bolster set vs. core and cavity
-
(00:06:21) Material procurement and standard vs. custom components
-
(00:09:01) Machining the tool: CNC, EDM, wire cutting, polishing
-
(00:11:12) Metal safe condition and first fitting
-
(00:11:59) The T0 trial run explained
-
(00:13:42) First look at molded parts and making big adjustments
-
(00:15:09) The T1 trial run with virgin polymer
-
(00:15:57) Inspection reports and customer sign-off
-
(00:18:00) Surface texturing between T1 and T2
-
(00:18:14) T2 trial – final tuning and sign-off preparation
-
(00:19:02) Phase gates link: tooling to mass production
-
(00:20:19) Golden samples and color consistency checks
-
(00:22:02) Why being on the ground in China helps with sign-off
-
(00:23:23) Limit samples and customer approval process
-
(00:23:55) The importance of T0–T2 for expectation management
-
(00:24:58) Why not to rush into mass production
-
(00:25:02) Links to prototypes and phase gate methodology
-
(00:26:05) Don’t sign off tooling until everything is consistent
-
(00:26:59) Moving into mass production and ongoing monitoring
-
(00:28:28) Tool lifespan and long-term considerations
-
(00:28:48) Wrapping up: intricacies of tooling complexity
-
(00:29:16) Sofeast NPI guide and related video resources
-
(00:30:16) Looking ahead: polymers and material selection
-
(00:30:45) Closing remarks and call to action
Related content...
-
How We Work With You On New Product Development & Manufacturing Projects - Agilian NPI Process
- Tooling Management for Plastic Injection Molds in China
- 7 Key NPI Tasks Before Production
- The Conundrum of Investing in Tooling Before a Final Prototype
- Inside the Tooling: Common Plastic Injection Mold Components Explained
- Understanding Plastic Injection Mold Tooling Complexity, from DFM to T1, When Manufacturing in China (Video)
-
- Connect with us on LinkedIn
- Contact us via Sofeast's contact page
- Subscribe to our YouTube channel
- Prefer Facebook? Check us out on FB
Popular Podcasts
Stuff You Should Know
If you've ever wanted to know about champagne, satanism, the Stonewall Uprising, chaos theory, LSD, El Nino, true crime and Rosa Parks, then look no further. Josh and Chuck have you covered.
Dateline NBC
Current and classic episodes, featuring compelling true-crime mysteries, powerful documentaries and in-depth investigations. Follow now to get the latest episodes of Dateline NBC completely free, or subscribe to Dateline Premium for ad-free listening and exclusive bonus content: DatelinePremium.com
The Male Room with Dr. Jesse Mills
As Director of The Men’s Clinic at UCLA, Dr. Jesse Mills has spent his career helping men understand their bodies, their hormones, and their health. Now he’s bringing that expertise to The Male Room — a podcast where data-driven medicine meets common sense. Each episode separates fact from hype, science from snake oil, and gives men the tools to live longer, stronger, and happier lives. With candor, humor, and real-world experience from the exam room and the operating room, Dr. Mills breaks down the latest health headlines, dissects trends, and explains what actually works — and what doesn’t. Smart, straightforward, and entertaining, The Male Room is the show that helps men take charge of their health without the jargon.