Tool design
Injection moulding, die casting and MIM tools | stamping, progressive and transfer dies
TB Müller is your provider for injection moulding, die-casting and MIM tools as well as stamping, progressive and transfer dies. With decades of know-how in metallic and thermoplastic materials, TB Müller offers well-founded tool design for a wide range of manufacturing processes. Simulations are used along the way to avoid change loops in advance and achieve good results from the start.
- Tool types
- Injection moulding, die casting and MIM tools · Stamping, progressive and transfer dies
- Scope
- Layout · Design · Filling study · Sampling · Dimensional inspection
- Tool versions
- Prototype tools · Single- and multi-cavity tools
- Special processes
- Gas injection · Core-back · Film and textile back-moulding · Insert technique
- Distinctive
- Our know-how from decades of experience.
Tooling technology in detail
Technology fields in which we successfully develop and design tools.
Multi-component technology & plastics processing
One, two or more materials in one tool — with all the layout decisions for gating, parting line, process control and the sequence of injection units. Just as decisive is the mechanics that makes a tool or functional part possible in the first place.
- 2K composite moulding
- Multi-colour moulding
- Film back-moulding
- Textile and fabric back-moulding
- Rotary tables and rotary tools
- Transfer and insert techniques
- Core-back technology
- Gas injection technology
Sheet metal processing
Stamping and forming tools for the economical series production of sheet-metal parts, designed for long tool life, process reliability and reproducible dimensional accuracy across the entire batch.
- Stamping dies
- Progressive dies
- Transfer dies
- Bending and forming tools
Die casting
Die-casting dies for the economical series production of complex parts, structurally optimised for mould filling, venting, temperature control and demoulding.
- Die-casting dies
- Combination with overmoulded inserts
- Thermal layout of the cavity
Metal injection moulding (MIM)
Tools for producing complex metal parts by metal injection moulding. The tool layout accounts for the particular demands of the highly filled feedstock as well as the subsequent debinding and sintering processes.
- MIM injection moulds
- Tool layout for highly filled feedstocks
- Cavity design for shrinkage and sintering
- Optimised gating and mould filling
- Wear-resistant design of the moulding surfaces
- Single- and multi-cavity tools
Decisive for the technical layout
Filling and flow study
Before the tool layout we evaluate flow paths, weld lines and holding-pressure behaviour as well as the expected pressure and temperature distribution in the part. This allows gating position, tool concept and process control to be optimised early and potential quality risks to be minimised before detail design begins.
Demouldability and parting line
Draft angles, undercuts and a tool-friendly parting line determine whether a visually convincing part can be produced economically at all.
Tolerance chains for automated assembly
Even before tool design we analyse and calculate the relevant tolerance chains across the entire assembly. This ensures that the individual parts interact reliably within their permissible deviations and that a process-reliable, cycle-stable assembly is guaranteed.
Cavity count and economics
Depending on volume, part geometry and the required cycle time, we lay the tool out as a single- or multi-cavity tool. Decisive are uniform mould filling and temperature control as well as process-reliable demoulding of all cavities — for reproducible part quality and economical series production.
Insert and overmoulding technique
Metal parts are positioned precisely in the tool and deliberately integrated into the plastic part. Coordinated part geometry, defined overmoulding zones and suitable anchoring elements ensure a secure positive connection and reproducible positioning in the series process.
Sampling and inspection
Before series release every tool is sampled under defined process conditions and the produced parts are dimensionally inspected. Evaluating the relevant quality and dimensional characteristics forms the basis for optimisation and finally confirms the tool's process and series capability.
Tool development — special processes and technologies
An example from a real project: a handle in which a coated metal hook is overmoulded, the shaft is formed hollow by gas injection and a soft component is then moulded on — all in one tool on a two-component machine.
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Assess the part
Assess wall thicknesses, functional surfaces and tolerances and define the technically suitable manufacturing process.
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Define the process
Number of components, sequence of injection units, transfer principle: rotary table, rotary core or insert technique.
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Filling study
Simulate flow paths, weld lines and holding pressure, optimise critical zones before tool manufacturing.
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Design the tool
Detailed layout of cavities, cooling, ejectors, gating and insert positioning.
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Sample
Produce first parts, measure them and compare against the design state.
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Release
Document the process window and release the tool for series production.
Frequently asked questions
Do you also build the tools yourselves?
We take on the tool design as well as the technical support through sampling and release. Manufacturing takes place at the client's tool shop or with proven partners — design responsibility stays with us throughout.
Can you design a tool for an already-designed part?
We check the part for demouldability, wall thicknesses and tolerances and point out necessary adjustments early — including their impact on tool concept, cost and schedule.
How many cavities make sense?
The optimal cavity count follows from annual volume, cycle time and part geometry. Whether single- or multi-cavity tool — decisive are uniform mould filling, temperature control and process-reliable demoulding of all cavities.
What is core-back technology?
In core-back technology, cavity space for a further component is created by deliberately retracting a tool core. The process enables multi-component parts without a rotary table and is particularly suitable where installation space is limited.
Do you design tools for existing machines?
Machine parameters such as clamping dimensions, clamping force, nozzle position and available core pulls are factored into the tool layout from the very beginning, ensuring a design optimally matched to the production machine.
