Expert & Customized Solutions
Stack Mold Manufacturer
Our stack molds are designed for maximum efficiency, providing you with competitive pricing and exceptional turnaround times. Improve your production capabilities while reducing costs with our ISO certified products.
What is a Stack Mold?
The Ultimate Efficiency Multiplier. A Stack Mold is a high-productivity tooling system featuring multiple parting levels. By stacking mold cavities vertically, it doubles or even quadruples production output on the same injection machine without requiring additional clamping force. It is the gold standard for high-volume manufacturing.
Applications of Stack Mold
Optimize your ROI by reducing energy consumption and machine overhead with stack mold solutions designed for high-volume, high-consistency manufacturing.
Thin-Wall Packaging
Medical Disposables
Personal Care
Housewares
Consumer Electronics
Automotive Parts
How To Work With Us
We know that outsourcing manufacturing can feel risky. We have designed our workflow to be transparent, communicative, and disciplined. Here is what happens when you partner with GBM:
Inquiry & ROI Analysis
It starts with a feasibility study. We don’t just quote; we analyze if a stack mold is the right fit for your volume. By doubling the parting surfaces, we help you project how much you’ll save on press tonnage and hourly rates. Within 24 hours, you’ll receive a technical proposal focused on maximizing your ROI.
01
Advanced DFM & Flow Simulation
Stack molds demand perfect balance. We perform rigorous Moldflow analysis to ensure simultaneous filling of both levels. We focus on the hot runner transition and thermal balance, predicting potential air traps or cooling imbalances before a single piece of steel is cut.
02
Synchronized Engineering Design
This is where complexity meets precision. Our engineers design robust rack-and-pinion or helical gear systems to ensure both levels open and close in perfect synchronization. We share the full 3D layout, highlighting the center block support and cooling manifolds, ensuring a stable "heart" for your high-speed production.
03
Precision Machining & Integration
A stack mold is two molds in one frame. We utilize high-precision CNC and EDM to ensure all cavities across different levels are identical and interchangeable. Every week, you’ll receive a progress report with photos/videos showing the assembly of the synchronization system and hot runner integration.
04
Dual-Level T1 Validation
The moment of truth. We test the mold in-house, meticulously checking the weight and dimensions of parts from both parting lines. Our CMM reports will verify that Level A and Level B are producing parts within the same tolerance zone, ensuring total consistency across all cavities.
05
Endurance Testing & Refinement
Stack molds are built for the long haul. We perform a high-cycle dry run to ensure the mechanical linkages operate smoothly without vibration. We apply final textures or coatings, then conduct a final stress test to guarantee the tool is ready for the rigors of millions of cycles.
06
Global Logistics & Technical Support
Stack molds are heavier and more complex. We treat them like precision instruments, applying multi-layer rust protection and secure vacuum sealing. Beyond delivery, we provide detailed maintenance manuals and spare parts kits for the synchronization components, ensuring your production never stops.
07
Why Global Manufacturers Choose GBM for Stack Molds?
Founded in 2012 in Shenzhen, GBM is a National High-Tech Enterprise with a 1,800m² state-of-the-art facility. We are an A-rated supplier (96 points) providing high-efficiency, high-volume tooling solutions for the world’s most demanding Tier-1 suppliers.
200% Productivity Boost
Our stack mold designs double the cavity count without requiring larger injection machines, effectively doubling your daily output.
Precision Hot Runner Integration
Expert integration of Husky/Yudo hot runner systems ensures perfectly balanced filling across all parting lines and levels.
High-Speed Synchronized Opening
Advanced rack-and-pinion or hydraulic linkage systems guarantee smooth, synchronized plate movement for cycle times under 10s.
Lower Part Cost (LCO)
Significant reduction in labor, energy, and machine overhead, offering a competitive edge for high-volume thin-wall or packaging parts.
GBM Stack Mold vs. Traditional Assembly
| Feature | Conventional Molds | GBM Stack Molds |
|---|---|---|
|
Output Capacity
|
Standard (1x)
|
Doubled (2x or more)
|
|
Machine Tonnage
|
Requires 2x Larger Machine
|
Fits Standard Machines
|
|
Energy Consumption
|
High (Per unit produced)
|
40% Lower (Per unit)
|
|
Labor Cost
|
Full Staffing Required
|
Minimal (Fully Automated)
|
|
ROI (Return on Investment)
|
18 - 24 Months
|
Fast Track (8 - 12 Months)
|
Our Partners
Know About GBM
Rooted in Shenzhen, the global hub of manufacturing, GBM combines a decade of engineering heritage with state-of-the-art facilities to deliver world-class tooling.
Our Certifications
We stand behind our products with a robust warranty and clear refund policy, ensuring your investment is protected.
The Ultimate Guide to Stack Mold by GBM
In today’s highly competitive manufacturing landscape, maximizing production efficiency without increasing equipment footprint is paramount. Stack molding has become central to high-volume output in the packaging, automotive, and medical device sectors. With over 20 years of hands-on mold experience, GBM simplifies complex multi-level tooling processes to help you double your production capacity and lower unit costs. Whether you require high-cavitation packaging solutions or intricate automotive components, GBM delivers comprehensive support from advanced hot runner design to mass production optimization.
Table of Contents
What is Stack Molding?
Stack molding is an advanced plastic injection process that utilizes multiple parting lines to “stack” two or more mold cavity faces on top of each other. This innovative configuration distributes injection pressure through a multi-layer structure, allowing a single standard injection molding machine to produce twice the number of parts per cycle without requiring a larger machine footprint or additional clamping force.
With over two decades of specialized mold manufacturing experience, GBM excels at designing these high-efficiency stack systems to help you achieve leapfrog production increases. By optimizing your mass production strategy with our custom stack molds, you not only save valuable factory floor space but also drastically reduce energy and labor costs per unit, bringing exceptional efficiency to your plastic injection process.
Why Choose a Tier 1 Stack Mold Manufacturer?
Partnering with a Tier 1-trusted stack mold manufacturer maximizes high-volume output by combining rigorous engineering precision with optimized multi-level mold architectures. This high-level expertise ensures that complex molds operate flawlessly, effectively doubling production capacity on existing injection molding machines while strictly maintaining consistent part quality and eliminating supply chain bottlenecks.
As a leading stack mold manufacturer with over 20 years of hands-on experience, GBM delivers exactly this level of reliability for global leaders like North American Yanfeng. By utilizing our brand-new, imported CNC equipment from Japan and Taiwan, we achieve the ultra-tight tolerances required for high-speed operation, ensuring a seamless transition from design to mass production while significantly lowering your unit costs and maximizing ROI.
How Hot Runner Systems Work in Stack Molds
Advanced hot runner systems act as the central circulatory system of a stack mold, meticulously balancing the flow and temperature of molten plastic across all cavity levels. This precise thermal and pressure distribution ensures synchronized filling at every parting line simultaneously, effectively preventing common process defects like short shots, flash, or uneven part weights across different layers.
Leveraging profound expertise in stack mold technology, GBM’s engineering team custom-designs these complex runner layouts to guarantee exceptional stability during high-frequency mass production. By integrating top-tier hot runner technology with our precision-machined mold components, we deliver the flawless consistency demanded by Tier 1 automotive suppliers, minimizing trial loops and accelerating your time-to-market.
Stack Molds vs. Standard Molds: Evaluating ROI
Evaluating the ROI between stack molds and standard injection molds requires analyzing your projected production volume, machine hourly rates, and facility constraints. While stack molds require a higher initial investment for design and manufacturing, they yield a rapid ROI for high-demand projects by doubling part output per cycle, thereby effectively halving the machine time, labor, and energy required to produce each individual part.
GBM provides comprehensive technical consulting to help you determine if your specific product volume justifies the transition to a high-efficiency stack mold system. Dedicated to mutually beneficial partnerships, we engineer solutions that deliver highly competitive unit pricing for our North American and European clients, transforming higher upfront tooling costs into long-term, exponential financial advantages.
The Importance of Precision CNC in Stack Molds
In the automotive and medical industries, the primary manufacturing bottleneck is often meeting massive volume demands within tight delivery schedules and strict quality tolerances. Complex stack mold designs solve this by instantly doubling a facility’s output capacity on existing machinery, allowing manufacturers to drastically accelerate production rates without the lead time or capital expense of procuring new injection presses.
GBM elevates this advantage by engineering highly integrated stack molds that incorporate advanced features, such as automatic thread unwinding, directly into the multi-level architecture. This innovative approach not only resolves supply chain bottlenecks for Tier 1 clients like Yanfeng North America but ensures every component maintains the uncompromising precision required by global markets.
Solving Production Bottlenecks with Stack Molds
In the automotive and medical industries, high-volume demands often create supply chain bottlenecks. GBM’s stacked mold design enables double output on a single machine, helping manufacturers effortlessly meet the challenging delivery cycles of Tier 1 suppliers like Yanfeng North America without additional investment.
Beyond speed advantages, we integrate complex functions like automatic thread removal within the stacked architecture. This highly integrated mold design not only resolves production bottlenecks but also ensures products maintain the high precision standards demanded by global markets while achieving high production efficiency.
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Frequently Asked Questions!
For high-volume production of thin-walled parts or caps, increasing the number of cavities on a single parting line often requires massive injection machines, leading to soaring energy costs and footprint. Our Stack Mold technology offers a breakthrough by doubling output without needing a larger tonnage machine.
We specialize in multi-level parting line synchronization and balanced hot runner systems. By leveraging high-precision rack-and-pinion or toggle mechanisms, we ensure stable opening and closing, achieving a 100% increase in productivity while maintaining strict dimensional tolerances for every cavity.
Yes. The primary requirement is sufficient opening stroke and plasticizing capacity. Stack molds do not require higher clamping force, allowing you to double production on the same tonnage machine.
We utilize advanced hot runner manifolds with equal flow path lengths and independent temperature control for each level to ensure identical pressure and melt temperature in every cavity.
Thanks to our use of premium mold steels (e.g., S136 or H13) and self-lubricating components, our stack molds typically reach 1,000,000+ cycles with standard scheduled maintenance.
It is ideal for high-volume, flat, or shallow parts such as container lids, petri dishes, thin-wall packaging, and automotive interior panels where cost-per-part is critical.
We employ heavy-duty rack-and-pinion systems or mechanical linkages to ensure all parting lines open and close simultaneously, preventing part damage and ensuring cycle stability.