Molding is the root industry of the manufacturing as a means to mass-produce developed prototypes. Molds are typically divided into injection molds and press mold industries. Injection molds produce the products by injection of molten plastic into a mold, and press molds are molded and bended plate. The ejection system, such as eject pins, is used to separate the manufactured products from the mold, which involves a number of hole operations. Location, diameter and depth of holes are often tabulated and managed collectively when designing 2D drawings. The design efficiency was realized by applying CATIA Automation to the 3D model and bringing in the data of the holes in the Excel data.

Recently, the engineering designer of injection mold has become more and more dependent on the CAE. In the design factors of injection mold, the shrinkage rate should be considered as one of the important performances to produce the reliable products. Therefore, the shrinkage rate can be mostly calculated by the MoldFlow and CATIA in the design process. However, it is not easy to predict the shrinkage rate of a plastic injection mold in its design process because the analysis can take minutes to hours, the high computational costs of performing the analysis limit their use in design optimization. In this study, the surrogate models based on the Taguchi Design in order to optimize the shrinkage rate of bevel gear injection mold is used instead of the original models, facilitating design optimal design.

The cylindrical gear in power window motor assembly is important to doors of automobile. This study is performed for purpose of getting a manufacturing technique instead of large quantities import and small cavity mold production. This multi-cavity cylindrical gear is produced under five procedures. The first, mold design of massproduction, the second, making a CAE model for mass-production, the third, manufacturing of sample mold, the fourth, trying-out and measuring of 3 dimensional design, the fifth, acquisition of data analysis and mold modification. Among them, analysis of mass-production using CAE, design and manufacturing of multi-cavity are successfully performed. In the results, it is concluded that mold for one gate and six cavity based on hot-runner is suitable for making a cylindrical gear.

Powder Injection Molding (PIM) has recently been recognized as an advanced manufacturing technology for low-cost mass production of metal or ceramic parts of complicated geometry. With this regards, design technology of dental scaler tip PIM mold, which has complex shape, with the help of computer-aided analysis for powder injection molding process was developed. Compter aided analysis results, such as filling pattern, weldline formation, and air vent position prediction were investigated and eventually showed good agreements with experimental results.