Our services:

  • New mold construction
  • Mold repair, refurbishing, conversions
  • Teflon® coating
  • Foam sample cutting
  • Pattern and model making
  • Contract machining
  • Contract aluminum castings
  • Reverse engineering

OUR SERVICES

Carroll Industrial Molds has a multitude of services to offer you as a vertically integrated full-service mold-maker, specializing in EPS, Thermoform, Urethane, and other aluminum molds. Our service areas include design, pattern, foundry, CNC, assembly, and coatings.

Design

Accurate information is essential to produce a quality mold. After an order is placed our design and project managers will work with you to produce an accurate and efficient mold design utilizing the latest design software and technology.

  • All new mold projects begin with the creation of a solid model of the finished part and corresponding cavities.
  • We can start with existing paper drawings, foam samples, models, or simply a part concept to create accurate tool layouts.
  • We can import your supplied data and specifications in a variety of electronic formats.
  • We can reverse engineer or verify existing products with state-of-the-art 3D digitizing equipment.
  • We utilize a solid modeling process to identify details from as obvious as mold plate/press interference issues to complex ejection and proper cooling water drainage problems which can be visualized and corrected at the design stage prior to the actual mold build.
  • Once a mold design has been approved, machining instructions are prepared to eliminate any chance of interpretation or translation errors and to insure an accurate mold build.

Pattern

Our skilled pattern-makers have years of experience building accurate, detailed patterns and models.

  • Close tolerance CNC machined patterns are built from Ren-Board, wood, aluminum, or plastic.
  • Reproductions are produced from models and samples.
  • Precise shrinkage and draft are tailored to customer specifications.

Foundry

Quality aluminum castings are produced in our in-house casting facility.

  • A no-bake process is utilized to produce aluminum castings ranging from 1 lb to 500 lbs.
  • Castings are produced from A356 primary alloy.
  • We can produce prototypes, one-offs, or short-run production castings.
  • The casting finish is excellent with many completed EPS molds shipped "as cast" with only minimal cavity polishing required.

CNC

We are committed to automated machining and are fully equipped with a several CNC vertical machining centers as well as a CNC turning center featuring:

  • Large-format capable with 120"x60"x26" capacity.
  • Machining centers with 50"x30"x24" capacity and 44"x30"x26.5" capacity.
  • Automated CNC turning center with automatic bar feeder.
  • Multiple CNC programming and design software seats with machine controls networked for efficient file transfers.
  • Proficient in CNC machined billet aluminum and in near net shape aluminum castings.

Assembly

Tasked with pulling all aspects of the mold building process together for final assembly, our experienced mold-makers are all proficient in:

  • Manual machining
  • Fabrication
  • Cavity venting - core vent and CNC precision hole
  • Cavity finishing and polishing
  • Welding – MIG. TIG, and gas
  • Cooling manifold design and placement
  • Pre-assembly fit-ups and inspections
  • Final completed mold inspection

Coatings

We offer complete "in-house" Teflon coating services, including:

  • New mold coating – cavity finished part surfaces, cavity backsides, and steam chamber surfaces (optional for corrosion resistance)
  • Used, refurbished, and repaired mold re-coating
  • Component and accessory coating – ejector heads, number and ID tags, and miscellaneous components
  • Additional features:
    • Curing oven capacity of 6' x 10'
    • Media blast room capacity of 10' x 14'
    • Genuine DuPont Teflon materials
    • Powder coating capability for accessory components
    • Mold disassembly and reassembly service if required
    • Timely turnarounds
    • Restored mold performance