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  • Brandon Henderson (NC) • Journeyman Tool & Die (CPSP)
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Product Sectors

Automotive and Heavy Industrial Components

Automotive molds are judged on three things: the part has to fit the car after it cools, the surface has to pass the eye of an OEM inspector, and the tool has to survive glass filled resin for the life of the program. TK’s standard mold business, where automotive is 81% of the work and home appliances 15%, builds for Tier 1 suppliers in Europe, which take about two thirds of its output, and North America, which takes about a sixth.

Part Families in TK’s Automotive Programs

  • Under hood, glass filled: fan shrouds, air filter housings and covers, convolutes, intake manifolds, coolant tanks, tubes, oil filter modules and roof parts, molded with pre distortion.
  • 2K, 3K and 4K: parts such as upper and lower air intakes, tried out on a 1,500 T Engel set up for 2K, MuCell and coining.
  • Extra large parts: HVAC housings, bumper fascias and grille frames, tried out on presses up to 2,800 T.
  • High gloss and exterior trim: grilles, chrome trim and door handles.
  • Lighting: headlamp housings and clear lenses.
  • Special processes: stack molds, MuCell and cross car beams.
Black front bumper fascia with grille openings and the mounting brackets above it, displayed in TK's showroom
Front bumper fascia and brackets in TK’s automotive showroom.
Two black honeycomb lower grilles and a chrome trim strip hanging on a pegboard
Lower grilles and chrome trim
Large black grille frame above a ribbed black automotive housing on a display wall
Grille frame and large ribbed housing
Black molded headlamp housing with three lamp openings
Headlamp housing
Clear molded headlamp lens
Clear headlamp lens
Interior door handle with a chrome lever and a high gloss black bezel
High gloss door handle with chrome lever
Both halves of an extra large TK automotive mold with slides, hydraulic cylinders and red support legs
Extra large automotive mold
Warpage Control

Pre Distortion for Glass Filled Under Hood Parts

Glass filled PA, PBT and PP shrink less along the fibers than across them, and thick and thin areas cool at different rates. A long shroud or tube that is perfectly straight in the steel can come off the mold and bow as it cools. Pre distortion is the fix toolmakers use: the core and cavity are cut with the expected warp reversed, so the same shrinkage pulls the part back to its drawing shape. TK opened a specialized tool room for 2K, pre distortion and high gloss molds in 2017, and lists shrouds, air filter housings, convolutes, intake manifolds, roof parts, coolant tanks, tubes and oil filter modules among its pre distortion parts.

Figure 1: How Pre Distortion Pulls a Warped Part Back to Nominal
A glass filled fan shroud with a ring, hub, ribs and a perimeter skirt, filled by two hot runner valve gates. Left, section A-A through the mold; right, the parting line face of the B half with the ejector pins, gates and cooling. In the first trial the steel is cut to the nominal shape and the shroud bows after ejection, and the scan maps it outside the tolerance band. The core and cavity are recut with the warp reversed, and in the next trial the same shrinkage pulls the shroud flat. A simplified illustration with the warp exaggerated.
Left, section A-A through a two plate mold for a glass filled fan shroud with a central ring, hub, ribs and perimeter skirt, filled by two hot runner valve gates. Right, the parting line face of the B half showing the shroud, ribs, ejector pins, gates and cooling. The first trial at nominal steel bows after ejection and the scan shows it out of tolerance. The core and cavity are recut with the warp reversed and the next trial shrinks straight into tolerance. SECTION A-A, SIDE VIEW PARTING LINE FACE, B HALF B HALF: CORE A HALF: CAVITY hot runner manifold, 2 valve gates STEEL RECUT: WARP REVERSED 3D SCAN Shroud: web, ribs, perimeter skirt, ring and hub. Glass filled PA. Pins under ribs and hub. A A ejector pinsvalve gates (A half)cooling scan: deviation map Deviation along section A-A tolerance bandnominal Trial 1, steel at nominalTrial 2, steel pre distorted Mold closed, steel cut to the nominal shroud shape Two valve gates fill the shroud with glass filled PA The part cools against the steel Mold opens and the pins push the shroud off the core Off the steel, uneven shrinkage bows the shroud 3D scan: the bow is outside the tolerance band Core and cavity recut with the measured warp reversed Next trial: the shroud is molded in the reversed shape Mold opens and ejects The same shrinkage now pulls the shroud flat 3D scan: the shroud is inside the tolerance band 1Trial at nominal 2Scan the warp 3Recut the steel 4Part shrinks flat Warp exaggerated for clarity. A simplified section: the first offset comes from Moldflow warpage results,and trial scans refine it. Shroud shape is an example of the glass filled under hood parts TK molds with pre distortion.

How TK Sets the Offset

  1. Predict: Moldflow warpage, cooling and wall thickness analysis in Autodesk Moldflow Insight, run by TK analysts who hold Moldflow medals: 1 gold and 3 bronze on the automotive team.
  2. Design: the offset is built into the core and cavity in UG NX, with gating and cooling set to keep shrinkage even.
  3. Trial and measure: scientific mold trials on TK’s own presses, then the parts are measured and compared with the CAD model.
  4. Correct: the steel is recut until the part lands in tolerance, and the changes go through TK’s ECR and optimization step before SOP.

The DFM and Moldflow review is where most warp is designed out, before any offset is needed.

Black glass filled under hood parts: a curved air tube, an oil filter housing and a fan shroud
Air tube, oil filter housing and fan shroud from TK’s pre distortion programs.
Mold Construction

Extra Large, 2K to 4K and Special Process Molds

Large automotive molds carry many slides, lifters and hydraulic cylinders, and every one of them has to clear before the part is ejected. TK’s automotive tool shop machines plates up to 3.2 m by 3.0 m by 0.8 m of travel, spots big molds on 7 die spotting presses and turns them on 12 mold reversal machines, and gun drills cooling lines on 5 deep hole centers, 2 of them 5 axis.

Both halves of a large TK automotive injection mold with slides, hydraulic cylinders and lifting points
Large automotive mold built by TK, shown open with core and cavity sides.
Multi shot2K, 3K and 4K moldsMolds for two to four materials or colors, tried out on a 1,500 T Engel set up for 2K, MuCell and coining. More on multi shot molding.
ProductivityStack moldsTwo parting lines in one mold, so each press shot fills two sets of cavities.
LightweightingMuCell and chemical foamingMicrocellular foaming, and core back with chemical foaming, to cut weight and sink on thick sections.
StructuralCross car beamsLarge structural molds for the beam behind the instrument panel.
SurfaceRHCM, Roctool and Color FormRapid heat cycle molding for a high gloss finish with fewer weld lines and stress marks, and Color Form surfaces.
EmergingSGI with 2K and IMESGI combined with 2K molding and IME (in mold electronics), on TK’s list of emerging automotive technologies.

Cooling for Big Steel

  • 3D printed conformal cooling on TK’s in house DMP 350 in maraging steel 1.2709, 33 to 37 HRC as built and 50 to 56 HRC age hardened, polished to SPI A2, with cycle time cuts of up to 35%.
  • Print size: 275 by 275 by 420 mm per insert.
  • Diffusion welded inserts as a second route to cooling channels that follow the part.
Half of a TK cross car beam injection mold with slides, hoses and red support legs
Cross car beam mold from TK’s special technology programs.
Mold Test

Trial Presses up to 2,800 T

A large mold is only proven when it runs in a press its size. TK tries out automotive molds on its own large presses before shipment, so slide timing, cooling, fill balance and part shape are proven before the mold ships. The newest is a 2,100 T Haitian added in March 2026.

1,000 TKraussMaffei
Large mold trials
1,500 TEngel
2K, MuCell and coining
2,000 T2K press
2K and spin form
2,100 THaitian, 2026
Newest large press
2,800 TLargest
Extra large molds
Side of a Haitian 2,100 ton injection molding press with an operator workbench and tool board
Haitian 2,100 ton press added in 2026 for large automotive mold trials.
TK's 2,800 ton blue injection molding press with a robot and an access platform, engineers at the mold area
The 2,800 T press in TK’s mold test area.

Ten Checks in Every Scientific Mold Test

Holding timeHolding pressurePressure lossShort shot balanceInjection speedMold and machine matchMold movementCooling circuitsMold temperatureMaterial temperature

Join the Trial from Your Desk

TK runs remote support on RealWear AR headsets, so your engineers can follow design and DFM reviews, project progress, the mold trial, sample and fitting checks and virtual validation of the mold without a flight. Project managers work one to one with each account in English, German, Spanish or French, and hold design reviews at your site when needed. When the mold ships it goes by air, sea or rail, vacuum packed and turnkey, with its certificates and documents. See how molds are prepared as export molds for U.S. presses and the full mold trial process.

TK engineer wearing an AR headset at a molding press control panel while a technician points at the screen
Remote mold trial support with an AR headset at TK.
Industrial Programs

Industrial, Appliance and Connector Tooling

Home appliances are 15% of TK’s standard mold business, and TK Group also builds precision molds for industrial electronics and connectors in glass filled engineering resins. These are TK’s own examples, with the mold data TK published:

Industrial electronicsHousing and base, PA66 + 25% GF
  • 4 to 16 cavities, 450 x 450 x 310 mm mold, 480 kg
  • 150 T, 25 s cycle
  • 776 dimensions, 15 at CPK above 1.33
Industrial electronicsLug insert, PBT + 30% GF
  • 32 cavities, 496 x 726 x 516 mm mold, 1,450 kg
  • 250 T, 15 s cycle, Elmax steel
  • Injection balance within 5%
Industrial, USA programUpper case, PP + 20T + GF30
  • 200 x 162 x 59 mm part, 201 g
  • 2 cavities, 1,040 kg mold, 280 T
  • 43.5 s cycle
ConnectorsConnector assembly, PET + 40% GF
  • 8 cavities
  • Metal inserts molded in
  • 160 T vertical press
ConnectorsElectrical cover, PEI + 10% GF
  • 14 x 15 x 12 mm part, 2 cavities
  • ±0.01 mm on the pins
  • 24 s cycle
ConnectorsHousing, PBT + 20% GF
  • 32 x 71 x 52 mm, 2 cavities, 100 T
  • Steel insert molded, 23 s cycle
  • RJG in mold sensing for process control
Large white molded appliance tub housing with radial ribs displayed in TK's showroom
Large appliance tub housing in TK’s showroom.
Black connector housings, switch bodies and small electrical components laid out in a TK display case
Connector housings and electrical components in TK’s display case.
Quality Documentation

IATF 16949 Quality and the Automotive Tool Shop

TK Group was first certified to IATF 16949 (2016 edition) in January 2021, on top of ISO 9001 since 1999. Every automotive mold runs through the same quality chain, from the steel that comes in the door to the after sales service on your floor.

IATF 16949Since January 2021
ISO 9001Since December 1999
ISO 14001Since June 2006
ISO 45001Since June 2018
ISO 14064-1Carbon verification
AEO AdvancedCustoms certified

The Quality Chain on an Automotive Mold

IQCIncoming steel: spectral check, hardness and dimensions
DFMDesign checked before steel is cut
IPQCPrecise in process inspection on the automatic CNC line
Mold inspectionThe finished mold checked before trial
Mold testScientific trial on TK presses
CMMSample measurement against the drawing
OQCRelease for shipment
After salesStart up and service support

TK’s Automotive Tool Shop

MachineQty
CNC milling machines109
5 axis and 4+2 axis CNC mills18
EDM machines68
Wire EDM22
Grinding machines and CNC jig grinders40 + 2
CMM and VMM / OGP20 + 5
Test presses, 2K included17 (3 are 2K)

From TK’s 2026 automotive presentation. The team: 100+ mold designers and 50+ tooling engineers, working in UG NX 8.5 and 12.0.

Supplier Awards from Automotive and Industrial Customers

CustomerAwardYears
MANN+HUMMELSupplier Excellence, Technology Excellence in 20242014, 2016, 2017, 2024
YanfengSupplier Excellence2016, 2017, 2018
FORVIAInternational Strategic Supplier2016
PhilipsSustainability Improvement2020, 2021
Planning Utility

Interactive Clamp Tonnage and Trial Press Calculator

Enter the size of your part, the cavities and the resin. The calculator estimates the clamp force the mold needs from the projected area and a rule of thumb clamp factor, then shows which of TK’s large trial presses it fits. Open “Show the math” to see every step with your numbers.

1The part, seen from the press
100 for a solid plate. Less for a frame, grille or shroud with large openings.
2The mold
0 for a hot runner to the part. Add area for a cold runner.
3The resin
Rule of thumb only. Long flow and thin walls need more.
Clamp force needed
0
Your mold against TK’s large trial presses
Cavity layout on the platen
Show the math
    Send my tonnage check to Brandon

    A first estimate. The clamp factors are typical rule of thumb values, not TK data. Real clamp force depends on flow length to wall thickness, gate layout, melt and mold temperature and the press, and TK confirms it with a Moldflow fill and pack analysis before the press is chosen. TK also runs smaller trial presses for molds below 1,000 T. Default numbers are an example only.

    Frequently Asked Questions

    Technical Sourcing FAQ: Automotive Tooling

    Is TK certified to IATF 16949?+
    Yes. TK Group was first certified to IATF 16949 (2016 edition) in January 2021. TK also holds ISO 9001 since 1999, ISO 14001 since 2006, ISO 45001 since 2018 and ISO 13485 since 2010, along with ISO 14064 carbon verification and AEO customs certification.
    What is pre distortion and when does a mold need it?+
    Pre distortion means cutting the core and cavity with the expected warp reversed, so the part shrinks into its drawing shape instead of away from it. It is used on long or open glass filled parts that warp after ejection, such as shrouds, tubes, intake manifolds, coolant tanks and roof parts. TK predicts the warp in Moldflow, builds the offset into the steel and corrects it from trial measurements.
    How large a mold can TK build and test?+
    TK’s automotive tool shop machines up to 3.2 m by 3.0 m by 0.8 m of travel, and TK tries out large molds on its own presses of 1,000 T, 1,500 T, 2,000 T, 2,100 T and 2,800 T. Use the clamp tonnage calculator above for a first check of which press your mold needs.
    Does TK build 2K, 3K and 4K automotive molds?+
    Yes. TK builds 2K, 3K and 4K molds for parts such as upper and lower air intakes, and tries them out on a 1,500 T Engel set up for 2K, MuCell and coining and a 2,000 T press for 2K and spin form. TK set up a specialized tool room for 2K, pre distortion and high gloss molds in 2017.
    Can my team join design reviews and mold trials without traveling?+
    Yes. TK runs remote support on RealWear AR headsets for design and DFM reviews, project tracking, the mold trial, sample and fitting checks and virtual validation of the mold. Each account has its own project manager, with English, German, Spanish and French in the team, and design review meetings can be held at your site.
    How are engineering changes handled during the build?+
    TK’s project flow runs from kick off and DFM with Moldflow through design checking and your approval, mold fabrication and in process checks, the first trial, then ECR handling and optimization before SOP and delivery release. Brandon Henderson coordinates changes for customers in the Americas with TK’s project manager.

    Have an Automotive or Industrial Program to Tool?

    Send your 3D models, resin, volumes and SOP date to Brandon Henderson, Technical Sales Support Manager for the Americas. He will review the part with TK’s automotive engineers for warp, slides and lifters, press size and multi shot options.

    Request Automotive Tooling Review Call Brandon: (336) 953-9664