Injection Mould Tool Making — Aluminium & Steel, Engineered Locally
From prototype aluminium bridge tooling to hardened steel production tools rated for a million shots, Forge Labs engineers and project-manages injection mould tooling with one Sydney-based tooling engineer — including full DFM, tooling CAD and T1 sampling.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why brands tool with Forge Labs
Tooling done with engineering rigour, transparent pricing and accountable local project management.
Aluminium Prototype Tooling
Cut in 3–5 weeks for bridge production runs of 100–10,000 parts at a fraction of hardened-steel tooling cost.
Hardened Steel Production Tools
P20, H13 and stainless tool steels for high-cycle production tools rated for 100,000 to 1,000,000+ shots.
Engineered Cooling & Gating
Conformal cooling, hot-runner systems and balanced multi-cavity layouts engineered for cycle-time and part quality.
DFM Before First Chip
Tooling-mouldflow review and gate optimisation before any tool steel is cut — catching issues at design, not at T1.
Sydney-Based Project Manager
Tooling is project-managed locally by a tooling engineer — one point of contact, accountable timeline, transparent pricing.
Our Workflow
From tool concept to T1-approved tooling
Tool concept & DFM
We review your part, target volume and cycle time. Tool layout, gating, ejection and cooling are engineered before quoting.
Tooling design & CAD
Full tool CAD is produced and shared with you — core, cavity, ejector plate, cooling channels and gating layout.
Manufacture & inspection
Aluminium tools are CNC-cut in 3–5 weeks; steel tools include heat treat and hand fitting (6–10 weeks).
T1 sampling & tuning
First-shot parts produced, dimensionally inspected and tuned in. Tool is signed off only after you approve T1 samples.
What we deliver
Tooling engineered before steel is cut
Mouldflow · Conformal cooling · Multi-cavity balanced layouts
A bad tooling decision is the most expensive mistake in plastic manufacturing — because the only fix is more tool steel and more weeks of lead time. Forge Labs engineers tooling thoroughly before manufacture: mouldflow simulation, gate placement, ejection pin layout, cooling balance and shrinkage compensation are all worked out in CAD before any chips fly. The result is tooling that delivers good parts on T1, not after three rounds of expensive rework.
- Aluminium tooling for 100–10,000 part bridge production
- Hardened P20 and H13 steel for 100,000 to 1,000,000+ shot production
- Mouldflow analysis and gate optimisation before steel is cut
- Conformal cooling and hot-runner systems for cycle-time optimisation
- Multi-cavity and family tools engineered for shot balance
- T1 first-shot sampling and dimensional sign-off before production
Materials
Tool steels we work with
The right tool steel for your shot volume, part finish and polymer abrasiveness — specified per job.
7075 Aluminium
BridgeLightweight, fast-cut aluminium for prototype and bridge production tooling — rated 5,000–10,000 shots.
P20 Pre-Hardened Steel
ProductionMid-grade tool steel for production tooling on non-abrasive polymers. ~100,000 shot life on standard cosmetic tools.
H13 Hot-Work Steel
High VolumeHardened high-grade tool steel for long production runs with abrasive glass-filled or carbon-filled polymers.
Stainless 420
Medical / OpticalCorrosion-resistant stainless for medical, optical and food-contact tooling that requires repeated polishing.
Industries we serve
What we tool for
From single-cavity prototype tools to high-cavitation production programmes for Australian and export brands.
Consumer Product Tooling
Cosmetic-finish steel tooling for retail-ready housings, packaging and accessories — typically 50,000–500,000 shot life.
Medical Device Tooling
Validated tooling for single-use medical disposables, fluid handling components and sterile-pack instrument bodies.
Automotive Tier-2 Tooling
Production tooling for under-bonnet clips, fasteners, sensor enclosures and aftermarket trim parts.
Electrical & Electronics
Insert-moulded brass terminal housings, EMI-shielded enclosures and panel-mount production tooling.
Industrial OEM Tooling
Replacement tooling for legacy products, second-source tooling for production resilience, and capacity-expansion tools.
Prototype-to-Production Bridge
Aluminium bridge tooling that proves the product, then transitions to hardened steel for sustained volume.
Showcase
Recent tooling work
Production-grade steel tool — cavity side polished to A2 finish.
Aluminium bridge tool installed and running first-shot samples.
Tool components on the CNC bed during manufacture.
FAQ
Frequently asked questions
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.