How It Works | From RFQ to Delivery — Injection Molding Process | JBRplas

From First Contact to Final Shipment

Every injection molding project at JBRplas follows a structured, documented process — from the moment you submit your 3D files to the day your parts arrive at your facility. Each phase has a defined owner, a committed timeline, and a deliverable. No handoffs between suppliers. No gaps in accountability.

Phase 1: RFQ & File Submission

You submit your 3D part files (STEP, IGES, SolidWorks, UG NX, or Pro/E format) and 2D drawings with your requirements: material preference, annual volume, cosmetic standards, target cost, and any regulatory constraints.

What we need from you:

• 3D part file (STEP preferred)
• 2D drawing with tolerances
• Target annual volume
• Material preference (or we recommend)
• Surface finish and colour requirements

Response time: Within 24 hours, you receive an acknowledgement and initial feasibility assessment. If the files are complete, a formal quotation follows within the same window.

Phase 2: DFM Analysis (Free)

Every quote at JBRplas includes a free Design for Manufacturability (DFM) review. This is not a checkbox exercise — it is a detailed written report prepared by a senior mold design engineer.

What the DFM report covers:

• Wall thickness uniformity and sink risk areas
• Recommended draft angles per surface texture
• Undercut analysis — eliminating unnecessary slides or lifters
• Parting line and ejection strategy
• Gate type and location options with trade-offs explained
• Estimated shrinkage and dimensional impact by material

If the part has manufacturability issues, we tell you before tooling begins — not after steel is cut. We recommend design modifications, explain the engineering rationale, and work with your design team to resolve issues at the CAD stage.

Timeline: 1–2 business days from file receipt.

Phase 3: Mold Design

Once the DFM is approved, our mold design engineers produce the complete 3D tooling design in SolidWorks or UG NX.

Design deliverables:

• Core, cavity, and slider geometry
• Runner and gate system (cold or hot runner)
• Cooling circuit layout (conformal or conventional)
• Ejection system (pins, blades, stripper plate)
• Lifter and side action mechanisms
• Mold base selection (LKM, HASCO, DME standard components)

Moldflow simulation (fill, warp, cooling analysis) runs before the design is finalized. If simulation reveals issues — asymmetric fill, unacceptable warpage, hot spots — we redesign at no additional cost.

The completed mold design is submitted to you for review and approval. We do not begin machining until you sign off. Typical design review turnaround from clients is 1–3 business days.

Timeline: 1–3 business days.

Phase 4: Customer Design Approval

You review the complete 3D mold design, Moldflow report, and steel specification. This is the formal check-point before machining begins.

What you approve:

• Mold design (3D model + 2D drawing package)
• Steel grade and hardness specification
• Gate type and location
• Surface finish specification (SPI or VDI)
• Ejection method and witness mark locations

Changes at this stage are free. Changes after steel is cut incur rework cost and time. We encourage thorough review — our engineers are available by email or video call to walk through the design with your team.

Timeline: 1–2 business days for design review and sign-off.

Phase 5: Mold Manufacturing

Once the design is approved, steel is ordered and machining begins. Our toolroom operates 12 CNC machining centers, 6 EDM sinkers, 4 wire-cut EDM machines, and 4 surface grinders.

Manufacturing sequence:

1. Steel procurement — P20, H13, S136, or NAK80 per specification
2. Rough machining — CNC milling of core and cavity blocks
3. Heat treatment — hardening and tempering to specified HRC
4. Finish machining — high-speed CNC to ±0.005mm
5. EDM — fine detail, ribs, and features
6. Wire-cut EDM — precision apertures, shut-offs
7. Grinding and polishing — surface finish to SPI or VDI specification
8. Assembly — mold base, ejector system, cooling circuits
9. CMM inspection — all critical dimensions verified against mold drawing

Timeline: 12–18 business days.

Phase 6: T1 Sampling

The completed mold is mounted on the appropriate injection press at JBRplas. T1 samples are molded using the production-grade resin specified for the project — not a cheaper substitute for trial purposes.

T1 trial protocol:

• Production-intent resin used (same grade as mass production)
• Process parameters recorded: injection pressure, temperature profile, cycle time
• 20–30 T1 samples produced for dimensional validation
• First Article Inspection (FAI) performed — all drawing dimensions measured on CMM

What you receive:

• T1 samples (shipped to your facility)
• Full FAI dimensional report
• Process parameter record
• Material certificate with lot number

Timeline: T1 samples ship 2–3 business days after mold completion. International courier delivery adds 2–5 business days depending on destination.

Phase 7: Customer Sample Approval

You evaluate the T1 samples against your part drawing, functional requirements, and cosmetic standard. This is the approval gate before mass production.

Typical customer evaluation:

• Dimensional verification (can cross-check against our FAI report)
• Fit and function test with mating components
• Cosmetic evaluation against agreed standard
• Material verification against specification

If adjustments are needed (dimensional tweak, surface finish refinement, minor gate modification), we implement the change, run a T2 trial, and re-submit samples — typically within 5–7 business days.

When samples are approved, production is released. For automotive programs, PPAP documentation is compiled and submitted at this stage.

Typical timeline: 1–3 business days for customer evaluation and approval.

Phase 8: Production

The mold enters production on the assigned press. Every production run follows a documented quality control process.

Production quality control:

Production volume: From 500-piece prototype batches to 5 million+ high-volume annual programs. Multiple presses can be allocated for programs requiring concurrent production.

Timeline: First production run ships 5–10 business days from sample approval. Repeat orders from stocked molds ship in 7–15 business days.

Phase 9: Quality Inspection & Delivery

Every shipment undergoes outgoing quality inspection before release. Documentation is compiled and shipped with the parts.

Standard documentation per shipment:

• Certificate of Conformance (CoC)
• Material certificate with lot traceability
• Dimensional report (AQL sampling data)
• Commercial invoice and packing list
• Country of origin certificate (on request)

Shipping options:

• Air freight (DHL, FedEx, UPS) — 2–5 business days
• Sea freight (LCL or FCL) — 15–30 business days depending on destination
• Rail freight to Europe — 12–18 business days

Incoterms: EXW, FOB Shenzhen, CIF, DDP — as agreed at order.

All export documentation is prepared in-house. HS code classification assistance is included.

Summary Timeline

These are committed timelines, not aspirational. They reflect our actual toolroom and production capacity.

What You Can Expect at Every Stage

• Single point of contact. One dedicated project engineer manages your program from RFQ to delivery. No handoffs. No repeating information.
• Proactive communication. You receive updates at every phase milestone. You never need to chase for status.
• Written documentation. Every phase produces a written deliverable — DFM report, mold design package, FAI report, CoC. Nothing is verbal-only.
• Realistic commitments. We quote lead times we can hold. When we commit to a T1 date, tooling is scheduled and capacity is reserved to meet that date.

Start your project — submit files for a free DFM review and quote →