Equipment and Facilities

5-Axis CNC Machining & High-Speed Milling Bays

The heart of our toolroom operations is an extensive bay of high-speed 3-axis and 5-axis vertical machining centers. Operating inside thermal-stabilized enclosures maintained strictly at 20 degrees Celsius, these machines mill hardened tool steels up to 60 HRC with sub-micron toolpath resolution.

• Mikron Mill X & HPM 5-Axis Centers: High-dynamics 42,000 RPM Step-Tec spindles equipped with laser tool measurement and infrared workpiece touch probes. Ideal for intricate optical lens inserts and complex contoured 3D parting lines.
• Makino V33i & D500 Graphite Milling: Dedicated dry-cutting graphite centers with advanced vacuum extraction, producing micro-detailed electrodes for complex electrical discharge machining with zero corner rounding.
• Yasda Precision Jig Borers: Specialized heavy-frame machines holding guide pin bores and slide pocket centerlines within plus or minus 0.001 mm across large multi-cavity mold plates.

Figure 1: Mikron 5-axis high-speed machining bay cutting complex automotive optical lens inserts.

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AgieCharmilles & Sodick EDM Precision Cells

For deep rib features, sharp internal square corners, and hardened steel details that cannot be reached by rotary end mills, TK Mold operates an automated electrical discharge machining (EDM) division:

• AgieCharmilles Form 3000 Sinker EDMs: Equipped with System 3R robotic pallet changers for lights-out 24/7 electrode swapping, digital generator controls eliminate surface recast layers and deliver mirror finishes down to Ra 0.1 μm directly from the spark.
• Sodick Linear Motor Wire EDMs: Utilizing 0.05 mm brass and tungsten wire with linear magnetic drive motors, achieving corner radii down to 0.03 mm for precision core interlocks and medical micro-fluidic channels.

Figure 2: Linear motor wire EDM cutting precision gate inserts submerged in deionized dielectric fluid.

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503-Machine Injection Press Fleet (6T to 1,500T)

TK Mold maintains one of the largest mold trial and contract molding press fleets in the global tooling industry. Having identical press models to our North American customers allows comprehensive factory acceptance testing (FAT) before tool export:

Our fleet includes premier global machinery brands:

• All-Electric Fleets: Sumitomo SE-EV and Fanuc Roboshot machines delivering micro-gram repeatability, ultra-clean operation, and high-speed injection response for thin-wall packaging and diagnostic disposables.
• Multi-Shot & Rotary Platens: Engel duo multi-component presses and KraussMaffei machines equipped with integrated servo rotary tables for 2-shot and 3-shot molding.
• High-Tonnage Hydraulic Presses: Haitian and KraussMaffei two-platen machines providing tie bar spacing up to 1,650 mm for automotive instrument panels and large industrial housings.

Figure 3: All-electric injection press bay with robotic sprue pickers and automated conveyor packaging lines.

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Medical Cleanrooms & Automated Finishing Lines

Beyond mold manufacturing, our campuses house vertically integrated secondary operations and cleanroom environments:

• Class 7 & Class 8 Medical Cleanrooms: Conforming to ISO 14644-1 standards with positive air pressure differentials, laminar HEPA filtration units, and gowning locks to prevent particulate contamination.
• Automated Spindle Spray Lines: 5-axis robotic painting cells with positive pressure clean air flow for high-gloss piano black and metallic coatings with zero particulate defects.
• Class 10k UV Coating & PVD Metallization: Physical vapor deposition chambers for chrome-look finishes on cosmetic caps and consumer wearable housings.
• Ultrasonic Welding & Automated Assembly: Branson ultrasonic welders, pad printing, and leak testing stations for turn-key finished sub-assemblies.

Figure 4: Automated robotic spray line with continuous spindle rotation for defect-free cosmetic coatings.

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High-Speed Spindle & Platen Dynamics

Visualizing the structural rigidity and thermal stability engineered into our 5-axis milling heads and high-tonnage press platens:

Toolroom & Production Machinery Specifications

Press Tonnage & Fleet Matching Selector

Input your part parameters to calculate required clamping force and match your program with our active injection press fleet:

Frequently Asked Questions: Equipment & Facilities