Plastic injection mould toolmaking

Faulkner Moulds, winner of UK Toolmaker of the Year 2019, 2018 and 2016, is celebrating 25 years of award-winning plastic injection mould toolmaking and product and tool design for manufacture. Combining traditional toolmaking skills with state of the art modern machining technology, 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.

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 million shot tooling guarantee on our mould tooling and serve many sectors including medical, electronics, packaging, consumer and automotive.

For more detail, scroll further down. Our range of services includes:

  • High quality award-winning plastic injection mould toolmaking
  • Design for manufacture principles
  • Complex tooling solutions
  • Mould tools for medical, electronics and packaging
  • Twin shot tools / two shot tools / 2K tools
  • 5-axis machining
  • Innovative wire erosion strategies
  • Component design full consultation service
  • Helping inventors develop ideas into a design ready for production
  • 3D printing / Stress Analysis
  • 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 and multi-cavity tools
  • High production tooling
  • Overmould tools
  • tons capacity
  • CNC machining
  • CNC sparking
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Faulkner Moulds

Plastic Mould Tool Maintenance and Repair

We offer a rapid response to your plastic moulding tool maintenance, repair and modification 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.

ISO9001 Quality Assurance

We follow rigorous testing, measuring and quality assurance protocols throughout each step of every plastic injection mould project, and we also offer a full tooling guarantee. We are the first company in the UK to own and operate a QCT Quantum 4 Coordinate Measuring Machine, reinforcing our commitment to maintaining our ISO9001:2015 certification.

Capacity

Faulkner Moulds, UK has facilities for full 3D CAD and CAM design including multiple SolidWorks and SolidCAM current licenses.  Our machining capabilities include CNC spark erosion, surface grinding, cylindrical grinding, turning and honing. We also operate a state-of-the-art high speed vertical 5-axis graphite machining centre, with a repeatable accuracy of 2 microns.

We have the machine capacity to tackle larger projects, to a weight of 3 tons. Our CNC machining and CNC spark erosion centres machine to a size of 1000 x 600 x 500, and spark with a tank capacity of 1200 x 800 x 400 deep, to a manufacturer’s stated accuracy of half a micron.

Our latest investment in Autumn 2019 is a top of the range Fanuc wire erosion machine (part funded by the European Regional Development Fund, via the University of York), 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.

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