Mold Testing and Validation Before Shipping

The mold trial process follows an industry-standard three-stage protocol that systematically identifies and resolves issues. The T0 trial is the first test of the completed mold, focusing on basic functionality: the mold opens and closes properly, all cavities fill, ejection works correctly, and the cooling system operates without leaks. T0 samples are typically evaluated only for completeness of fill and basic dimensional conformity, with surface quality and cycle time optimization addressed later. The T1 trial occurs after T0 corrections, which commonly include adjustments to gate sizing, venting modifications, cooling circuit optimization, and ejection system refinements. T1 focuses on achieving target dimensions, acceptable surface quality, and preliminary cycle time evaluation. For HWAMDA thin-wall molds, T1 typically targets 80-90% of the final production speed. The T2 trial validates production-ready performance, confirming that the mold achieves target cycle times, all cavities produce parts within dimensional tolerances, and the mold runs continuously for a minimum of 4-8 hours without interruption.

Dimensional testing verifies that molded parts conform to the product drawing specifications across all critical dimensions. For thin-wall food containers, the key measurements include overall height, top diameter, bottom diameter, wall thickness at multiple points (typically gate area, mid-wall, and far-gate regions), rim flatness, and stacking ledge dimensions. HWAMDA's quality lab uses calibrated digital calipers, micrometers, and coordinate measuring machines (CMM) for precise dimensional verification across all cavity samples. Wall thickness measurements use ultrasonic thickness gauges providing non-destructive readings at multiple locations around the circumference and along the container height, creating a comprehensive thickness profile. Weight testing is equally critical for thin-wall packaging, as it directly reflects filling completeness and process consistency. Each cavity's average weight and standard deviation are calculated from the sample set of 5-10 consecutive shots. For yogurt cups, the target weight tolerance is typically plus or minus 0.3 grams. The cavity-to-cavity weight spread should not exceed 1-2% of the target weight for a properly balanced mold.

Visual quality evaluation assesses surface appearance against reference standards or approved limit samples. For food packaging, key visual criteria include surface gloss uniformity, absence of flow lines and weld lines in visible areas, gate vestige quality, and freedom from cosmetic defects such as scratches, burn marks, or contamination from degraded material. HWAMDA evaluates samples under standardized lighting conditions, examining both interior and exterior surfaces of each container against the approved reference standard. Gate vestige quality receives particular attention in thin-wall packaging because consumers directly handle these containers during daily use. Valve gate systems, standard on HWAMDA thin-wall molds, produce flush gate vestiges with no protrusion above the container surface. The gate mark diameter, typically 2-3 mm for thin-wall applications, should show no stringing, drooling, or discoloration. For IML containers, additional visual criteria apply: label position accuracy within plus or minus 0.5 mm, label adhesion with no peeling or bubbling, and consistent label appearance across all cavities.

The formal acceptance protocol defines the criteria and process by which the customer approves the mold for shipment. HWAMDA's standard acceptance package includes dimensional inspection reports for all cavities, weight analysis with statistical summaries, photographic documentation of samples from multiple angles, production rate validation data including cycle time logs, and a video recording of the mold running at production speed. All measurement data is compiled into a structured trial report with clear pass or fail designations against each specification. Customer acceptance can be conducted in person at HWAMDA's facility in China or remotely through video conference with real-time sample inspection. For remote acceptances, HWAMDA ships sample sets to the customer for independent verification while providing all digital documentation. Upon acceptance, the mold undergoes final preservation treatment: all surfaces are coated with anti-corrosion agent, cooling circuits are purged and sealed, and the mold is packed in a moisture-barrier wooden crate suitable for ocean freight.