PLASTIC INJECTION MOULD TOOLMAKING

Faulkner Moulds, three times winner of UK Toolmaker of the Year, has over 25 years of award-winning plastic injection mould toolmaking and product and tool design for manufacture. Continually investing in and pioneering toolmaking technology and skills, Faulkner Moulds UK toolmakers produces long lasting, high production and low maintenance plastic mould tools.

Through our dedicated design consultation service, we will help you create a manufacturing process that runs as smoothly and efficiently as possible, creating high quality plastic injection moulds.

As Design for Manufacture specialists, we always consider fully how the tooling will be used in practice, and incorporate this into each design. Therefore, we regularly reduce costs for our customers in the short, medium and longer term.

We offer a full 1 or 2 million shot tooling guarantee on our mould tooling and serve many sectors including medical, electronics, packaging, consumer, industrial and automotive.

For detail on our machining capacity, scroll further down. Our range of services includes:

 

  • Reverse engineering
  • Fully hardened tools
  • Graphite machining / electrode machining
  • Stripper plates
  • Side movers
  • Unscrewing cores
  • Up and aways
  • Hot runner, conventional or 3-plate feed
  • Single impression and multi-cavity tools
  • Overmould tools
  • tons capacity
  • CNC machining
  • CNC sparking
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Faulkner Moulds

CAPACITY

Faulkner Moulds, UK has facilities for full 3D CAD and CAM design including multiple SolidWorks and SolidCAM current licences.  Our machining capabilities include CNC spark and wire erosion, surface grinding, cylindrical grinding, turning and honing. Our state-of-the-art high speed vertical 5-axis graphite and hard metal machining centre enables automation of electrode manufacturing and die face finish machining, achieving a repeatable accuracy of 2 microns.

Our newest machines include a top range wire erosion machine, which allows us to create innovative wire eroded toolmaking solutions, on parts up to 1250 x 975 x 500 and is able to achieve mirror finishes with maximum accuracy. Our new CNC spark erosion machine is guaranteed to machine to a constant accuracy of 3 microns. Our suite of high specification CNC machinery will machine to a maximum of 1000 x 600 x 500.

Our versatile new Hurco TM8i 2 axis CNC turning centre (lathe) has in-built features to ease programming, enhance machine speed and ensure outstanding accuracy and surface finish. It is ideally suited to the fast-paced demands of modern toolmaking. Faulkner Moulds’ recent experience in high precision turning includes projects for the medical, packaging and industrial sectors.

In summer 2022, we again installed trail blazing technology at our Yorkshire-based toolroom. Our innovative robotic production cell is a truly a ‘world first’, further enhancing the quality and efficiency of our mould tool manufacture. The production cell particularly supports multi-cavity, high-production tooling.

The pioneering manufacturing cell will feed both the Mikron 5-Axis and Sodick spark erosion machines, enabling automated changes of electrodes and of workpieces, increasing capacity for high cavity tooling.

ISO9001 QUALITY ASSURANCE

As an ISO9001 certified company, we follow rigorous testing, measuring and quality assurance protocols throughout each step of every plastic injection mould tool project, and we offer a full tooling guarantee. Our Mitutoyo Crysta-Apex S CNC Co-ordinate Measuring machine responds to increased demand for ever tighter tolerances in toolmaking, allowing highly accurate 3D measurements at high speed. Dedicated software algorithms guarantee high accuracy by eliminating even miniscule geometrical imperfections in the guideways.

PLASTIC MOULD TOOL MAINTENANCE AND REPAIR

We offer a rapid response to your plastic mould tool modification, repair and maintenance needs, including an on-site service.

This can include a preferential maintenance service on a contract basis, to ensure your production needs are covered with minimal interruption. Our experience includes a call-out maintenance contract for Motorola mobile phone tooling.

RAPID TOOLING

We always strive to meet your most urgent tooling requirements. Our hours of business can be flexible and it is possible for us to provide a rapid response to any plastic injection mould tool making emergency.

Faulkner Moulds