Carroll Industrial Molds is a vertically integrated full-service mold-maker. The Company offers a multitude of services including custom mold design, specializing in EPS, EPP, EPE, Thermoform, Urethane, and other aluminum molds. Our in-house service areas include mold design, pattern, casting, CNC machining, assembly, and specialty coatings.
- New mold construction
- Mold repair and refurbishing
- Mold conversions
- Spareparts and components
- Teflon® coating
- Mold design and solid modeling
- Reverse engineering
- Foam sample cutting
- Pattern and model making
- Aluminum casting
- Contract machining
- Design
- Pattern/Casting
- CNC
- Assembly
- Coatings
Mold Design
Accurate information is essential to produce a quality product. After an order is placed our design and project managers will work with you to produce a detailed and efficient design utilizing the latest solid modelling design software and technology.
- All new projects begin with a customer supplied solid part model, or if not available, we can create a solid part model for customer approval.
- We can utilize existing paper drawings, foam samples, working models, or simply a part concept to create accurate solid part models and/or mold 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 SolidWorks to produce production details and identify potential problem areas. On a mold build, solid modeling allows identification of specific mold details; such as interference issues, ejection concerns, proper cooling, water drainage and/or other problems.
- Issues identified and visualized at the design stage enable adjustment prior to the actual production process.
- Once a design has been approved and released, production instructions are prepared to ensure an accurate project completion.
Casting
- Precise shrinkage and draft are tailored to customer specifications.
- Pattern and casting solid model configurations are produced in SolidWorks.
- Close tolerance CNC machined patterns are built from Ren-Board, wood, or aluminum
- Quality aluminum castings are produced in our in-house casting facility.
- All castings are poured from A356 primary alloy.
- The no-bake process is utilized to produce aluminum castings ranging from 1lb. to 500 lbs.
- 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 centers. Featuring:
- Haas GR-712 gantry vertical mill: X 145.00”, Y 85.00”, Z 24.00”
- Haas GR-510 gantry vertical mill: X 121.00”, Y 61.00”, Z 11.00”
- Haas VF-6SS vertical mill: X 64.00”, Y 32.00”, Z 30.00”
- Haas VF-5 vertical mill: X 50.00”, Y 26.00”, Z 25.00”
- Haas VF-3YT vertical mill: X 40.00”, Y 26.00”, Z 25.00”
- YCM WV-108A vertical mill: X 44.00”, Y 30.00”, Z 27.50”
- Haas DS-30Y turning center with 4’ bar feeder: 18.00” dia., 23.00” length
- YCM GT-250B turning center with 4’ bar feeder: 16.53” dia., 20.27” length
- Multiple seats of SolidWorks, HSMWorks, and Mastercam CAM programming software.
- All Haas CNC machines equipped with wireless intuitive on-machine probing.
- Proficient in CNC machined billet aluminum and 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′
- Genuine DuPont Teflon materials
- Powder coating capability for accessory components
- Mold disassembly and reassembly service if required
- Timely turnarounds
- Restored mold performance
