Bumper and fascia moulds, up to 2,000 mm.
A bumper is judged twice: by the paint line, which will not tolerate a sink mark, and by the assembly jig, which will not tolerate a 1 mm gap. Both are tool decisions, taken months before the first shot.
Flow length sets the gate, the gate sets the surface.
A 1.8 m bumper has a flow path long enough that a single gate will freeze before the ends fill. That is why large fascias use sequential valve gating: the drops open in order, the flow front stays a controlled line, and the last place to fill is not a cosmetic face. Getting the sequence wrong shows up as weld lines across the visible surface, and no amount of polishing removes them.
Surface texture is cut into the cavity, not painted on afterwards. A grained cavity hides flow marks and gives the paint something to key to; a polished cavity shows every defect. We agree the grain standard — usually a VDI or a customer-supplied plaque — before the block is textured, because re-texturing after trial is a two-week setback.
The third job is dimensional: bumper ends, mounting tabs and the grille opening all have to land inside the assembly jig. We hold those features in the tool drawing, check them on the CMM at trial, and send the report with the tool. If your customer's jig is available, we would rather match it than match a nominal CAD tolerance.
Built around a big press
Bumper tools are 1,600–3,200 t work. We build them with sequenced hot runner, generous cooling and slides sized for the wrap-around ends, then move them on the shop crane rated for the job.
- Cavity and core: 718H or S136 ESR for painted, high-gloss surfaces.
- Gate: sequential valve gate, 2–6 drops, opening order defined in the mould design.
- Cooling: multi-zone, symmetric left-to-right, with separate circuits for ends and centre.
- Slides: two large side slides for the wrap-around ends, wear plates on the cam.
- Ejection: ejector pins off the non-visible face, plus air assist on thin sections.
- Texture: grain applied to an agreed plaque standard, protected during trial.
What the trial report contains
Trial parts are measured on the CMM against the drawing and, where supplied, against the assembly jig. The report lists critical dimensions, gate trim condition, weld-line locations, and the process window we used. Photos of the first-off parts go with it, so your quality team can review before the tool ships.
What we build to
| Typical part size | Up to 2,000 mm flow length, 3–6 kg shot weight |
|---|---|
| Cavities | 1, or 2 for smaller fascias |
| Cavity steel | 718H, S136 ESR for painted class-A surfaces |
| Gate | Sequential valve gate, 2–6 drops |
| Cooling | Multi-zone, symmetric, separate end circuits |
| Cycle time | 60–90 s |
| Tool life | 300,000–1,000,000 shots |
| Press tonnage | 1,600–3,200 t |
| Lead time | 14–18 weeks from design freeze |
Class-A surface, grain standard and assembly jig tolerances are the three inputs that move both price and lead time. Send them with the 3D — quoting a bumper without them is guesswork on both sides.
Questions from Tier-1 and Tier-2 buyers.
How much does a bumper mould cost?
It is one of the largest tools in a vehicle programme, and the price depends on flow length, gate count, slide size and grain standard. Send the 3D, the annual volume and the surface requirement; we reply with a specification-based quotation rather than a range.
Can you match a grain or texture from an existing part?
Yes. Send a physical sample or the texture plaque reference (VDI 3400 or the OEM standard). We have the cavity textured to that standard and protect it through trial so the first parts and the ten-thousandth part read the same.
Do you handle the trial in-house?
Yes, on our own presses within the tonnage range, with CMM measurement and a written report. If the tool needs a press larger than we run, we trial at a partner shop with our engineer present and issue the same report.
What about PP versus PC/ABS?
PP is the volume material for unpainted fascias; PC/ABS is used where the part is painted or needs higher stiffness at temperature. The choice changes shrinkage, cooling and occasionally the gate size, so it belongs in the quotation, not in the trial.
Send the fascia data, get a tooling specification.
3D model, annual volume, surface class and jig tolerances. You get cavity count, gate sequence, steel grade and lead time in writing.