Die Cast Tooling and Mold Design Suppliers

case study
case study
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the problem
A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.
the solution
The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.
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Why PHB is a Leader Among Tooling, Mold Design and Repair Companies

  • With a fully stocked mold and die component inventory we provide short lead times on repairs
  • We assure continuous, high volume, trouble free molding through innovative validation
  • From small to large, single cavity to multi cavity, our mold design capabilities are unmatched
PHB Corporation specializes in tooling design and machining and repair. For over 40 years, PHB has been a global supplier of high pressure plastic injection molds, high quality aluminum and zinc die-cast dies, and specialized machining. In addition to the design and production of molds and tooling, we are the most extensive mold and die repair company in North America.

Quality Mold Tooling & Die Casting Die Manufacturing

PHB is committed to the continual upgrading of machinery and equipment to ensure we offer a state of the art mold tooling and die casting die manufacturing facility. We provide tooling and specialized machining for contract manufacturers that includes high pressure injection molds for high pressure valves, nuclear components, large gearing and mechanical drives. We also provide turnkey services beyond our mold manufacturing including creating initial designs and prototypes for the molds, manufacturing the tooling, designing custom fixturing, and providing the die cast part production. PHB’s size, lift capacity and machine capability — comprised of high-speed machining centers, state-of-the-art CNC sinker EDM machines and extensive engineering expertise — sets us apart from our competitors.

Some of our capabilities include:

  • Product design
  • Injection mold tooling design
  • Die Cast Die design
  • Mold and Die construction (100 to 2000 ton capacity)
  • Mold and Die repair
  • Tool validation

Validation Technology and Mold Flow Analysis

Our die cast and mold designers utilize the latest technology in engineering and metal flow analysis. We understand that our ability to provide your company with superior quality and lower cost hinges on technology and innovation.

Some of our technology includes:

  • MAGMAsoft® flow technology

Other engineering software used includes:

  • Pro Engineer/CREO
  • AutoCAD

choose phb for your tool & die manufacturing needs today

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