MoldCalc Pro
Mold Suite
mm
in
🎯
Mold Costing — Detail Panel
Exact Tooling Cost
🔩 Clamp Tonnage
Part L
–
Part W
–
Cavities
–
Mold base
–
mm
📊 Tonnage Results
Output
⚡ REQUIRED CLAMP TONNAGE
–
Tonnes
Area per cavity–
Runner area–
Total projected area–
Cavity pressure–
Raw clamp force–
Part weight
–
g / part
Shot weight
–
g total
⚙️ Machine Match
Recommendation
SELECT MACHINE BRAND
📂
Drop 3D part file here
STEP
IGES
STL OBJ 3MF
🔒 Offline
🧪 Plastic Material
Select material to auto-fill melt temp, shrinkage & cavity pressure across all tabs
✅ After upload:
Part dimensions & volume auto-filled → Go to
📐 Mold Size tab
to continue calculations.
📂
Upload STEP / IGES / STL to view
drag to rotate · scroll to zoom
Iso · Normal
drag · scroll to zoom
Press Esc or click ⛶ to exit fullscreen
Upload a 3D part file on the left to run DFM analysis
📐 Mold Base Inputs
Step 02 · Mold Size
Mold Config
Part Dimensions
Part Length
mm
Part Width
mm
Part Height
mm
Number of Cavities
Cavity Layout
Along Length
Along Width
2 × 2 Grid
Custom Grid
Part Orientation in Mold Base
Single cavity — Part Length placed parallel to Mold Base Length automatically.
Mold Type
Sliders
Lifters
pcs
Enter any quantity (no limit)
Part Ejection
mm
Leave blank — software will auto-estimate. Enter the actual ejection travel your part needs (e.g. 60, 80, 100 mm) to get the correct total mold height.
Part Volume & Weight
cm³
If you have exact volume from CAD/SolidWorks, enter here. Otherwise calculated from dimensions + wall thickness.
mm
Used only when CAD volume not entered.
📏 Mold Base Results
Output
⚙ Adjust Mold Base
Length
— mm
Width
— mm
Thick
— mm
INSERT SIZE
Insert Length
–
mm
per insert
Insert Width
–
mm
per insert
MOLD BASE SIZE
Mold Base Length
–
mm
L dimension
Mold Base Width
–
mm
W dimension
Mold Thickness
–
mm
STEEL & VOLUME
Est. Total Steel Weight
–
kg
full mold
Mold Volume
–
cm³
total cavity
🔲 Insert & Cavity Design
Step 03 · Insert & Cavity
📐
Part & material data from Mold Size & Tonnage tabs
Part L
–
Part W
–
Part H
–
Wall
–
Material
–
Cavity and core insert heights equal — standard split
⬌ Fine-tune Parting Line
50% in cavity
All Core
All Cavity
0%
← Core depth | Cavity depth →
100%
mm
Custom cavity side height override
mm
Custom core side height override
Insert Material
Steel grade affects insert cost, mold life and machinability
Insert Design Parameters
↺
mm
Auto: 30mm (small) · 45mm (with sliders) · 50mm (>200mm part) · Click ↺ to reset to auto
Insert Height Override (Optional)
💡 Leave blank to auto-calculate. Enter custom values to override.
🔍 Part View — Parting Line
Live Sync
Rotation: X 0° · Y 0° · Z 0°
Box
2.0×
Zoom
1.0×
PL
Load a 3D part to activate
📦 Insert Size Results
Output
Core Insert (Moving Half)
Insert Length
–
mm
Insert Width
–
mm
Insert Height
–
mm
Cavity Insert (Fixed Half)
Insert Length
–
mm
Insert Width
–
mm
Insert Height
–
mm
Insert Steel Weight (both halves, per cavity set)
–
kg
〰️ Runner & Gate Design
Step 05 · Runner & Gate
📐
Part & material data auto-filled from Mold Size & Tonnage tabs
Part Vol (est.)
–
Cavities
–
Runner Dist
–
Material
–
Viscosity
–
Material
Wall Thickness
mm
Gate height, runner diameter and gate width are all based on wall thickness
Part Volume
cm³
Enter exact volume from CAD/3D software — or leave blank to use estimated value from part dimensions
Runner System
Gate Style
📏 Runner & Gate Results
Output
Runner Diameter
–
mm
circular
Runner Width
–
mm
trapezoidal
Runner Depth
–
mm
Gate Width
–
mm
Gate Height
–
mm
Gate Length
–
mm
Sprue ⌀ Small End
–
mm
Sprue ⌀ Large End
–
mm
Sprue Length
–
mm
= mold thickness
Sprue Taper
–
°/side
📚 Rules of Thumb
GATE LOCATION
Always place the gate at the thickest section of the part. This ensures the thick area packs out fully before the gate freezes, preventing sink marks and voids.
TUNNEL / SUBMARINE GATE DIAMETER
Gate diameter = ½ × wall thickness (0.5t to 0.75t). Minimum 0.8mm for most materials. Smaller gates give cleaner de-gating but increase shear stress — check against material's max shear rate.
GATE TOO SMALL
Causes: high shear stress → material degradation, excessive pressure loss → short shots, jetting, burn marks, and premature gate freeze before packing is complete → sink marks.
GATE TOO LARGE
Causes: long gate freeze time → longer cycle time, large gate vestige → secondary trimming needed, difficult de-gating, risk of backflow when screw retracts.
RUNNER DIAMETER
General rule: Runner ∅ ≥ Part wall thickness. Typical range 3–10mm. Keep runners as short as possible to minimise pressure drop and material waste. Balance multi-cavity runners so all gates fill simultaneously.
FLOW LENGTH RATIO
Flow length ÷ wall thickness should be ≤ 150 for unreinforced materials, ≤ 100 for glass-filled. Beyond this, filling pressure becomes too high. If exceeded — add gates, increase wall thickness, or switch to hot runner.
SPRUE DESIGN
Sprue small-end diameter: ≥ 3.5mm (never smaller than largest runner). Taper: 1°–3° per side for easy ejection. Length = mold thickness — keep as short as possible. Sprue puller pin essential for two-plate molds.
WELD LINE AVOIDANCE
Weld lines form where two flow fronts meet. They are weaker than the base material (10–40% strength reduction for GF materials). Place gates so weld lines land in non-critical or hidden areas. Add a vent at the weld line to prevent burn marks.
HOT RUNNER NOZZLE SELECTION
Open tip: suitable for crystalline materials (PP, PA, POM). Valve gate: best for amorphous materials (ABS, PC, PMMA) and cosmetic parts where zero gate vestige is required. Valve gate adds RM 4,000–8,000 per drop.
GATE VESTIGE & COSMETICS
Tunnel gate: auto-de-gates, vestige ≤ 0.5mm. Edge gate: requires manual trimming, vestige 0.5–1.5mm. Fan gate: very low vestige but wide mark. Hot tip: near-zero vestige. Valve gate: zero vestige. Choose gate type based on cosmetic requirements of the A-surface.
MATERIAL-SPECIFIC NOTES
Select a material above to see specific gate and runner recommendations.
❄️ Cooling System Design
Step 06 · Cooling System
🌡️
Material temperatures auto-filled from Tonnage tab selection
Standard melt & ejection temperatures loaded per material. Adjust if using specific grades.
Standard melt & ejection temperatures loaded per material. Adjust if using specific grades.
Material
–
Wall Thick
–
Part Vol (est.)
–
Melt Temp
–
Eject Temp
–
Cavities
–
Material
Coolant Settings
°C
Recommended: auto from material (15–25°C chiller / 40–60°C tower)
sec
Temperature Override (optional — leave blank to use material defaults)
°C
°C
Cycle Time Factors
Affects gate freeze / hold time
More gates → shorter flow length
🌊 Cooling System Results
Output
Cooling Time
–
sec
Total Cycle Time
–
sec
estimated
Channel Distance
–
mm
from surface
Channel Pitch
–
mm
Heat to Remove
–
kJ/shot
Coolant Flow Rate
–
L/min
🔩 Cooling Circuit Layout
Circuits / Core
–
lines
Circuits / Cavity
–
lines
Total Circuits
–
lines
Recommended Channel Ø
–
mm
💰 Mold Cost Estimator
Step 07 · Mold Costing
Insert type: separate inserts dropped into plates — better repairability, higher precision, suitable for long runs.
📐
Mold dimensions auto-filled from Mold Size tab
Go to Tab 1 to change part details. All values update automatically.
Go to Tab 1 to change part details. All values update automatically.
Mold L
–
Mold W
–
Mold T
–
Part L×W×H
–
Cavities
–
Sliders
–
Additional Components
pcs
Auto-synced from Mold Size · editable
pcs
Auto-synced from Mold Size · editable
⚠ Part Geometry Complexity HIGH COST IMPACT
Affects machining time and EDM cost. Simple: no add | Medium: +RM 3k | Complex: +RM 8k | Very Complex: +RM 15k
⚠ Mold Grade & Industry MULTIPLIER
Applies grade multiplier to final quote. Automotive/medical molds need premium engineering, documentation and trials.
⚡ Mold Life & Tolerance AFFECTS COST
Higher life → harder steel → higher material + machining cost
Tight tolerance → precision machining + extra QC cost
Design & Engineering Costs
Secondary Processes
🏢 Company Cost Profile
📊 Cost Breakdown
Output
💰 GRAND TOTAL MOLD COST
Market-rate quick estimate
–
MYR
📋 Cost Breakdown Detail
| 🔩 Material Costs | |
| Mold Base Plates (C45 structural steel) | – |
| Insert Steel (core + cavity) | – |
| Total Material Cost (steel) | – |
| ⚙️ Manufacturing Summary | |
| Mold Base (supplier — LKM/standard) | – |
| Machining (CNC / EDM / Wirecut) | – |
| Labour | – |
| Finishing, Testing & Delivery | – |
| Profit (%) | – |
| 📋 Full machining breakdown → Exact Tooling Cost tab | |
| 📐 Design & Engineering | |
| 🎨 Secondary Processes | |
| 🔩 Standard Components | |
| Ejector pins, latch locks, O-rings, angular pins & misc | – |
| GRAND TOTAL | – |
| Cost per Cavity | – |
Currency: MYR | Malaysian Ringgit (MYR)
🧩 Part Production Cost
Step 10 · Part Cost
🔗
Mold cost, cavities & cycle time auto-filled from previous tabs
Mold cost from Costing tab · Cavities from Mold Size · Cycle time from Cooling tab
Mold cost from Costing tab · Cavities from Mold Size · Cycle time from Cooling tab
Mold Cost
–
Cavities
–
Cycle Time
–
Part Wt (est.)
–
Runner Wt
–
Material
–
Material
$/kg
Auto-set from material selection
LIVE MARKET PRICE — FROM BENCHMARK DB
Min
—
Avg (Use This)
—
Max
—
Select material to see market price
Mold Life & Amortization
pcs
Shot Life
500k
Mold Life (yrs)
—
Amort/Part
—
Maint/Year
—
Machine & Labour
🏭 Machine Hourly Rates — From Company Settings
Click a bracket to use that rate · Highlighted = auto-selected from tonnage tab
Production Settings
×
%
%
📊 Part Cost Results
Output
Cost per Part
–
USD
Selling Price
–
USD
with margin
Material / Part
–
USD
Machine / Part
–
USD
Mold Amort. / Part
–
USD
Parts per Hour
–
pcs/hr
Revenue at Target Volume
–
USD
Cost Breakdown
Material
Machine
Mold Amort
Maintenance
Annual Mold Maintenance
–
per year
Maintenance per Part
–
per part
Break-Even Analysis
| Volume | Cost/Part | Mold Payoff |
|---|
📊 Benchmark Configuration
India Market 2026
📐
Your mold cost auto-loaded from Costing tab
Configure industry & precision class to compare against India market benchmarks
Configure industry & precision class to compare against India market benchmarks
Your Mold Cost
—
Mold Size
—
Cavities
—
Industry Category
Precision Class
Part Size Category
📈 Benchmark Results
India Market 2026
📊
Run benchmark to see verdict
Configure industry & precision class then click Run
📊 INDUSTRY BENCHMARK RANGE (INDIA 2026)
Low
—
YOUR COST
—
High
—
YOU
← UNDERPRICEDCOMPETITIVEOVERPRICED →
Cost Factor Analysis
Industry Range Comparison
▼
📋 Full Project Summary
File & Tools
🕒 Project History
Saved locally · max 10 projects
No saved projects yet — click "Save to History" to save current project
🏢 Company Branding & Report Settings
⬜ No company set
📷 No logo
🔢 Quote: auto
📁 Project Information
No image selected
ℹ️
Fill in project details above · Complete all tabs · Use 📊 Mold Break-Up Sheet for full cost report · Use 📷 Capture in Part Analysis for 3D view
📅 Mold Lead Time Estimator
Based on complexity, cavities & features
⚡
Auto-filled from your mold configuration. Adjust any field to fine-tune the estimate.
⚡ Auto-filled from other tabs.
Parameters below are synced automatically. Click any section to override manually.
Project Settings
Lead Time Breakdown
📅 ESTIMATED DELIVERY
–
Days
–
–
Project Timeline (Gantt)
⚠ Lead times are estimates based on standard toolroom workflows. Actual times depend on shop capacity, material availability and design freeze date. Add 15–20% buffer for first-time projects.
Attribution: Exchange rates by ExchangeRate-API
Attribution: Exchange rates by ExchangeRate-API
🎯 Exact Tooling Cost Calculator
Bottom-Up Costing
💡 This calculates your actual manufacturing cost from first principles —
material + every machining operation + overhead. Use this before buying steel or placing orders.
Currency & Market (linked from Mold Costing tab)
Steel Material Rates (auto from market · edit to override · ↺ reset)
/kg
/kg
/kg
/kg
Mold Dimensions (auto-filled from Mold Size tab)
mm
mm
mm
mm
mm
Part Complexity & Features
Machining Rates (auto from market · edit to override)
/hr
/hr
/hr
/hr
Machining Hours (auto-calculated · edit to override · ↺ to reset)
Calculating…
Calculating…
Calculating…
Calculating…
Calculating…
Calculating…
Calculating…
Calculating…
Additional Items
Overhead & Profit Margin
%
Electricity, machine depreciation, coolant, tooling wear
%
At 20% profit: selling price = cost × 1.20
📊 Cost Breakdown
—
Fill inputs and click Calculate Exact Cost
✅ Pre-Order Verification
Run calculation first to see checklist
🔩 Standard Components Calculator
Misumi · DME · Hasco · Meusburger
💡 Calculates ejector pins, latch locks, angular pins, O-rings and other standard purchased components based on mold size, cavity count and mold type. Cost estimates based on regional market rates.
🏭 Supplier
Part refs shown below
Auto-filled from Mold Size Tab
Mold Configuration
Each boss = 1 sleeve ejector pin · 0 = no sleeve ejectors
🔩 Pin Grade
Override (leave 0 for auto — all sizes calculated from part dimensions)
Auto: based on part size
Auto: insert H + 50mm
Auto: Ø20 or Ø30 by slider size
📋 Component BOM & Cost
—
Fill inputs and click Calculate
📌 Engineering Notes
Run calculation to see notes