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This client is a UK-based logistics company specializing in cold chain transportation. In November 2024, they placed an order with Alpine Mold after discovering our website through a Google search. They were specifically seeking a highly experienced partner in large part injection molding to help develop a cabinet door frame used in their refrigerated transport systems.
The plastic part required for this project measured 1800 mm x 790 mm x 85 mm, placing it firmly in the category of injection molding for large parts. Due to the part’s size and structural requirements, the client needed assurance that we had the capabilities to handle large plastic molds with precision and efficiency.
During the initial discussions, this client expressed concern about whether Alpine Mold could manufacture such large injection molds, (as the final mold size would reach 2.5 meters x 1.8 meters). To build trust and demonstrate our capacity, we implemented the following measures:
1. Arranged a live virtual tour of our factory, highlighting our technical strength and production scale.
2. Provided a detailed list of equipment, proving we were equipped for large scale injection molding.
3. Shared our successful project references, especially in automotive large part injection molding, to demonstrate relevant experience.
large part plastic mold
large part plastic mould
large part injection molding
Through this comprehensive approach, we gained this client’s full confidence and successfully began cooperation on this complex large part plastic injection molding project.
As part of this large part injection molding project for the refrigerated cabinet door frame, the most critical technical challenge arose during the mold trial phase. After demolding, the part exhibited noticeable deformation after resting—a result of insufficient internal structural support in the door frame area, leading to inward shrinkage.
To overcome this issue and ensure structural stability for such large plastic injection molded parts, we implemented the following engineering solutions:
1. Boiling Process for Stress Relief
We immediately applied a boiling water treatment to effectively release internal stress from the molded PA6-GF30 component. This helped the part return to its original intended shape and prevented further warpage.
2. Custom Shaping Fixture Design
We designed a dedicated shaping fixture that provided continuous support to the large molded part during cooling and post-processing. This guaranteed long-term dimensional stability and preserved the integrity of the final product.
Thanks to these corrective measures, the updated samples were quickly approved by this client. The project has since moved into full-scale mass production, reinforcing Alpine Mold’s reputation as a reliable partner for large part molding and injection moulding large parts with demanding technical requirements.
The freezer compartment housing required precise control over part strength, warpage, and dimensional accuracy—critical factors for its performance in cold chain logistics. To meet these high standards，Alpine Mold followed a rigorous, step-by-step Large Part Injection Molding Process：
1. Fast Quotation
Provided a detailed quote within 24 hours based on 3D design, material, and technical specs.
2. DFM & Mold Flow Analysis
Conducted in-depth analysis to optimize gate location, wall thickness, and cooling, minimizing warpage and improving strength.
3. Large Mold Design
Engineered a robust mold structure to handle the large size and complex geometry.
4. Large Mold Manufacturing
Used premium-grade steel and advanced machining equipment to produce durable, precise molds.
5. Mold Trial & T1 Approval
Completed successful testing on a 2000-ton machine; T1 samples met all key criteria and were fully approved by our customer.
By successfully completing this complex and time-sensitive large part injection molding project, Alpine Mold demonstrated our technical expertise, speed, and commitment to quality. We delivered the 23.8-ton mold and freezer compartment housing within just 45 days, meeting this client’s strict requirements for dimensional accuracy, strength, and durability—critical for cold chain logistics.
Our fast delivery gave the client a key time-to-market advantage, earning their trust and a long-term partnership. If you are looking for a trusted partner for your large part plastic injection molding projects—especially for applications requiring high structural integrity and dimensional control—Alpine Mold is here to help.
