Blow Molding Mold Design Challenges

In hollow product processing, plastic hollow blow molding and extrusion blow molding are highly favored for their lightweight properties, high productivity, and versatile applications. However, to achieve stable mass production of high-quality products, mold design and manufacturing must overcome many challenges. Dih Hong Plastic specializes in blow mold design and manufacturing, addressing these common technical bottlenecks from the source.

Common Challenges and Solutions

1. High Complexity of Mold Design

• Challenge: Hollow blow molding requires highly precise mold design, particularly for multi-layer structures, irregular shapes, and products with uneven wall thickness.
• Solution: Dih Hong applies mold flow analysis, 3D modeling, and mold simulation design to ensure proper cavity dimensions, blowing behavior, and cooling layout—reducing trial runs and tooling risks.

2. Difficulty in Controlling Material Properties

• Challenge: Material melt flow, thermal shrinkage, and wall thickness uniformity significantly affect product quality.
• Solution: Based on different plastics (HDPE, PP, PETG, etc.), Dih Hong provides tailored mold design parameters and assists customers in adjusting blow molding conditions for stable performance.

3. Insufficient Cooling System Efficiency

• Challenge: Improper cooling channel design can lead to uneven cooling, warpage, wall thickness variation, or extended cycle times.
• Solution: Dih Hong optimizes cooling circuits and mold base materials, improving cooling efficiency and overall molding stability

4. Dimensional Accuracy & Precision Issues

• Challenge: Blow-molded products are affected by air pressure, wall thickness deviations, and mold deformation, leading to dimensional errors.
• Solution: By integrating high-precision CNC machining and air pressure control system design, Dih Hong ensures consistent product dimensions and fit accuracy in mass production.
  
  

5. Demolding Issues

• Challenge: Poor demolding may damage products or prolong molding cycles.
• Solution: Dih Hong optimizes draft angles, mold surface roughness, and lubrication treatments, minimizing sticking risks and extending mold life.

6. Other Critical Technical Factors

• Parison Control Technology: Determines wall thickness distribution and symmetry; Dih Hong provides multi-point wall thickness control systems.
• Clamping Precision & Mold Rigidity: Ensures seam quality and dimensional stability; Dih Hong uses high-rigidity mold frames and professional fitting techniques.
• Mold Materials & Heat Treatment: High-wear steels such as 2316 and S136 with nitriding or hardening treatments extend service life.
• Mold Maintenance & Life Cycle Management: Preventive maintenance guidelines and repair services are offered to improve operational efficiency

Dih Hong Plastic，Delivering Efficient and Reliable Blow Mold Solutions

With years of practical experience in blow mold manufacturing and hollow blow molding technologies, Dih Hong Plastic provides:

• Extrusion, injection, stretch, and multi-layer co-extrusion mold design
• High-precision multi-cavity molds, irregular-shaped molds, and large-scale blow molds
• Integrated hollow blow mold manufacturing and trial molding services
• Support for automated molding systems and recycled material applications

We don’t just deliver molds—we provide comprehensive engineering consulting and technical support, helping customers achieve three key goals from the development stage:stable mass production, energy savings & carbon reduction, and product innovation.