From concept to manufacturable product

Injection mold manufacturing: From engineering to first-time-right

From concept to a directly manufacturable plastic product — without costly iterations or trial-and-error. At PEZY we engineer injection molds that perform perfectly from the very first run. All under one roof in our own mold-making facility and Pilot Factory in Groningen.

From idea to perfect mold: The analysis phase

The foundation for a mould that performs perfectly from the very first run

At PEZY, we never start with milling. We always begin with a thorough analysis of your product, application and ambitions. We combine your knowledge with our more than 30 years of experience in plastics engineering.

In this phase, we carry out fast and focused iterations where needed. This is exactly where our strength lies: we can run this process much faster and more efficiently than most others. This allows us to fully optimise the design before the mould is built.

The result? A well engineered mould that performs reliably from the very first injection moulding run. Any adjustments are made during the engineering phase, not during costly production runs.

Product and use scenarios

We directly translate your product and its actual operating conditions into the optimal mold design. Mechanical loads, temperatures, chemical exposure and user interactions are all factored in from the start. You can leave the technical complexities to us. The result is a mold that fits your end product and its real-world application perfectly.

Production volume and cost targets

Whether you need prototypes or small to medium sized production runs, we determine the most suitable mould strategy. Aluminium, steel or hybrid? We take full responsibility for the material choice and execution. Based on the technical requirements and economic considerations, we choose the smartest solution for your project.

Functional integration

We take release systems, cooling circuits, inserts and complex geometries into account at an early stage. This ensures the mould is technically sound and functions correctly in practice from the start.

Sustainability and circularity

Sustainability starts with smart design and the right material choices. We actively advise on PCR materials, biobased plastics and reducing the CO₂ footprint. Where needed, we use a test mould to minimise risks, helping your production run without delays or downtime.

Simulations and engineering

Mold flow, FEA and thermal analysis combined with practical experience.

At PEZY we completely engineer the mold before any steel is cut. Using advanced simulations including mold flow, FEA and thermal analysis, we obtain fast and reliable insight into the product’s performance.

However, software never tells the complete story. That’s why we always combine these simulations with over 30 years of hands-on experience. We identify potential risks at an early stage and validate them in practice where necessary.

This way we create a mold that delivers outstanding performance right from the first shot: optimal filling, minimal shrinkage, perfect cooling and high-end surface quality.

Mold flow simulations

Using mold flow simulations, we optimize gate placement, fill pattern and pressure distribution within the mold. This delivers uniform filling, minimal internal stresses and low differential shrinkage. The result: a stable, repeatable production process with significantly less scrap and excellent part-to-part consistency.

Strength calculations

Using advanced strength and stiffness analyses, we thoroughly evaluate the product. We accurately predict its performance under load, pressure and prolonged use. This way we prevent unexpected breakages or deformations during production or in the hands of your customers, ensuring a reliable, high-quality end product.

Thermal management and cooling circuits

A well-designed cooling system is essential for a stable and efficient injection molding process. We optimise cooling channels to ensure the product behaves as consistently as possible. This makes warpage and shrinkage predictable and repeatable, enabling us to maximise output using the optimal process parameters. The result is consistently high-quality parts with tight tolerances and a superior surface finish straight from the mold.

Lossing en ontluchting

Excellent ejection and venting eliminate common injection molding issues like air traps, burn marks, vacuum formation and visible ejector pin marks. We carefully design the ejector system and venting channels to ensure the part is released smoothly and without damage. The result is a clean, high-quality finish directly from the mold, reducing post-processing and costs.

From concept to a production-ready mold

Design that is ready for production.

We translate the outcomes of simulations and analyses into a fully manufacturable mould design. In doing so, we take into account all practical aspects that matter in real production: functionality, service life, ease of maintenance, cost efficiency and reproducibility.

Every detail is aligned with your needs. We optimise wall thicknesses, tolerances, injection points, draft angles and rib structures so the product is not only technically sound, but also efficient and reliable to produce.

Whether it concerns a simple housing, a precision component or a complex mechatronic product with inserts and multiple components, our mould design is ready for series production from the very first drawing. You avoid surprises during mould construction or in the injection moulding machine, costly adjustments afterwards, and get a mould that runs correctly from the start, with a long service life and low maintenance costs. This saves time, money and risk at every stage of your project.

Material choice for molds

At PEZY we carefully select the optimal mold material for every project, based on your product, required production volume, technical specifications and budget. From rapid prototyping and small series to high-volume production, we always choose the material that offers the best technical performance and economic value.

We work with aluminium, steel and hybrid constructions. Circular plastics do not require any exotic mold materials. We optimise the mold specifically to process recycled and circular materials effectively, or to test whether your material performs well when switched to a circular grade. This way you get a mold that fits your project perfectly, without needing to worry about material specifications.

Aluminium molds
Hybrid solutions
Circular and sustainable options

Prototyping, validation and first-time-right

Sampling and trial production in our Pilot Factory

Before moving a mold into series production, we thoroughly test it on our own injection molding machines in Groningen. This forms a key element of our first-time-right philosophy. We run samples, measure all critical parameters and make adjustments where necessary. Only after full validation and approval of a “golden sample” do we authorise series production.

This process removes any surprises and guarantees that your mold runs reliably and consistently from the very first production shot.

Mechanical functionality

We test whether all moving parts, snap fits, hinges and other functional elements work exactly as intended. By using real injection moulded parts, we identify potential weak points in the design that may not always be visible in simulations. This ensures the product is strong, reliable and user friendly in practice.

Cycle time and reproducibility

We optimise and measure cycle time down to the second. We also verify reproducibility across multiple production runs. This creates a stable process with minimal variation between parts. The result: efficient production with consistent quality and a lower cost per unit.

Surface quality and tolerances

We measure gloss, colour consistency and critical tolerances using precise measurement equipment. Any sink marks, flow lines or other aesthetic and dimensional deviations are identified and resolved immediately. This allows us to deliver parts that meet the highest standards, both technically and visually.

User and assembly evaluation

Alongside technical measurements, we also test how the product performs in practice. Does assembly run smoothly? Does the final product feel right for the user? Are there any hidden issues during assembly or everyday use? This hands-on evaluation ensures that the product works not only on paper, but also in the hands of the end user.

Preparation for series production

DFM optimisation and smooth handover

Once the mould has been successfully validated in our Pilot Factory, we optimise it for actual series production. We prepare everything to ensure a seamless transfer to your production partner, whether in the Netherlands or with one of our selected partners in Asia.

With complete technical documentation, detailed specifications and hands-on support during the first production runs, we ensure rapid scale-up without compromising quality or causing unnecessary delays.

Design for manufacturability

Production strategy & partner selection

We advise on the best production strategy based on volume, desired lead time, budget and quality requirements. Whether you prefer local production in the Netherlands for maximum flexibility and short communication lines, or a partner in Asia for larger volumes — we select and guide the right manufacturing partner and ensure a seamless handover.

Samples and golden sample

We deliver a set of approved samples along with a final golden sample. This acts as the definitive benchmark for series production. Every critical specification, tolerance and aesthetic requirement is clearly recorded, ensuring your production partner knows precisely what is expected.

Support in the production phase

Even after the mold is handed over, we remain fully supportive. We assist during the first production runs, help with fine-tuning as needed, and rapidly resolve any issues that arise. This results in a fast ramp-up and a stable, reliable production process from day one.

Developing a successful mold together

At PEZY, more than 30 years of combined expertise in plastic engineering, mold manufacturing and injection molding come together under one roof. This allows us to confidently handle projects that others often consider too complex, too small or too time-critical.

Whether you need a technical housing, a high-precision component or a complex mechatronic product, we provide a fully integrated solution. From the very first analysis to successful series production, our focus is always the same: a mold that performs perfectly right from the initial run and a product that can be produced reliably and efficiently.