Wire Harness Plastic Injection Tooling

Wire Harness Plastic Injection Tooling

This is the wire harness plastic injection tooling for our USA customer. they are the world famous leader for the automotive and instrument wire harness. Asia Billion have more than 30% business are the wire harness and plastic connector molding and tooling project. If you come to our plant, you can see huge quantity samples in our site.

Product Details

Asia Billion is a custom high precision connector plastic injection molding and wire harness plastic injection tooling manufacture. This project is for the automotive lighting industry for our USA and Canada customer. they are the world leader for the  wire harness and plastic connector. the material is PA66 with GF33 engineering material from Dupont.  Totally are 2 sets insert mold with 4 cavities.

Production details:  


connector plastic injection molding

Core surface  finish:

Matt finishing

Production     Material:


Cavity surface finish:

Matt finishing

No of Cavities:

4 cavity

Injection System

Cold  runner

Core Material:

LKM S136 with heat treatment HRC 48 to 52

Type of gating:

edge gate

Cavity Material:

LKM S136 with heat treatment HRC 48 to 52

Ejection system:

Ejector pin

Slider and  lifter  material:

4 sliders , LKM S136 with heat treatment HRC 48 to 52

Lead time for T1

5 weeks

Mold base:

LKM standard

Shot life:

1 000 000


Product Characters:

1) Complex design which need to put the wires, IC and metal insert before the molding

2) Strictly control for the IC and metal insert and need to pass the x-ray scanning inspection

3) Assembly and function testing for each item

4) High precision with +/-0.05 mm critical dimension tolerance

Asia Billion Advantages for this project:

1) Asia Billion is a high quality and cost competitive precision injection mold and molding manufacture

2) Asia Billion top management team all can speak English and can talk with you directly to give you more support

3) Asia Billion are the expert for wire harness plastic injection tooling and connector plastic injection molding tools. each year we made more than 100 sets this type mold and 20 million molding parts

4)  Asia Billion are trustable partner for you. we are honest and transparent for our clients.


Asia Billion Injection tooling quality control:


Asia Billion Injection Tooling Quality Control

Asia Billion injection tooling plant view:

Injection Tooling Quality Control


   The wiring harness is the most commonly used accessory product of people. Injection molding is required in the production process of the wiring harness. Injection molding is to encapsulate the manufactured data cable port. Because the injection molding equipment needs to be installed the the accessaries before injection molding a wiring harness.  After injection molding, the product needs to be ejected and collected. During this process, because the lower mold is still occupied, the existing injection molding equipment cannot be used at this time, the machine is idle, working efficiency is low and the corresponding production higher cost.

 Here highlights a new type of special wire harness plastic injection tooling used by Asia Billion. Through our design, we can provide a continuous and efficient injection mold of wire harness, which can realize the injection molding operation while we are inserting the wires and inserts. Normally the injection parts at both ends of the wire harness are basically connector plastic injection molds, which are often highly accurate, and there are many wire harnesses and hardware inserts. It is not easy to insert, not easy to locate, and the product has high added value, but the production efficiency is very low, so the traditional solution is high cost.

  In order to solve the above technical problems, Asia Billion innovatively uses a wire harness continuous and efficient injection mold, including an upper mold, a first lower mold and a second lower mold. The first lower mold and the second lower mold are centrally symmetrically arranged on the installation base plate, and are matched with the upper mold for injection molding through the rotation of the mounting base of the injection molding machine. When the first lower mold is under injection molding, and the second lower mold is in front of the operator, it is convenient for us to place the wire harness and the insert, which doubles the production efficiency.

  The detail working steps are here , First, place the wire harness in the first lower mold cavity, move the first lower mold below the first upper mold, close the mold and do the injection molding, at the same time, the operator can place the wire harness and insert into the second lower mold while injecting. After the injection of the first lower mold is completed, the mold is opened, and the first lower mold is moved at the same time, so that the second lower mold is moved below the first upper mold, and injection molding is continued. At the same time, the first lower mold cavity has been injected, The completed wire harness is taken out, and a new wire harness is placed at the same time. After the second lower mold is injected, the mold is opened and the first lower mold is moved below the first upper mold again. This is repeated to achieve continuous and efficient injection molding of the wire harness .

   At the same time, the number of products always is large. When used for a long time, the mold core is easy to be damaged. If the mold core is of an overall structure, any part of the mold core is damaged, the entire mold core needs to be replaced, which affects the use and production supply, the repair and replacement of the large mold core  is expensive , inconvenient transportation and high cost Here Asia Billion In order to meet the mold life requirements with quality assurance, we use multiple inserts, and all large inserts are cooled,  some easily damaged inserts we made 2 to 3 sets of spare Parts, which increases the service life of the mold and saves costs. It also can help customer have a stable production supply capacity.

   Asia Billion are the expert for the wire harness plastic injection tooling , connector plastic injection mold and their injection molding production.   They are our main business which are more than 30% percentage of our total turnover and we have great advantages comparing with others , we have lower price , better precision and faster lead time.  Please contact us freely if we can help you too.

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