Dual-Color Power Tool Handle Mold

1. Project Overview
This OEM/ODM project demonstrates the development of a rotary dual-shot injection mold for power tool handles requiring integrated rigid and soft-touch material structures. The reference project involved a 210 × 60 × 45 mm handle component using a 1+1 cavity configuration and P20 tool steel, followed by mold design review and trial production. The tooling was developed for handle components where structural strength, grip areas and bi-material integration need to be considered within the same molded part.

2. Rotary Dual-Shot Mold Development
• Rotary Dual-Shot Process: Uses a rotary mold configuration to form compatible rigid and soft-touch materials through a coordinated dual-shot molding process.
• Bi-Material Integration: Integrates structural and grip-contact areas into one component according to the approved handle design.
• 1+1 Cavity Configuration: The reference project used a 1+1 cavity arrangement based on the component structure and molding requirements.
• P20 Tool Steel: P20 steel was specified for the reference mold according to its tooling and production requirements.
• Handle Structure Development: Mold design considers handle geometry, material transition areas and assembly-related features for power tool applications.

3. Grip & Structural Integration
• Soft-Touch Grip Areas: Soft-material sections can be positioned around designated contact areas according to ergonomic and product-design requirements.
• Rigid Structural Areas: The rigid substrate provides the main structural form required by the power tool handle design.
• Material Interface Control: Mold development considers the transition and bonding areas between compatible soft and rigid materials.
• Integrated Molding: Dual-shot processing reduces the need to manufacture the soft and rigid sections as separate handle components.
• Surface Definition: Soft-touch and rigid surface areas can be differentiated according to the approved CMF and product requirements.

4. Mold Review & Trial Production
• Mold Design Review: Tooling structure is reviewed before trial production to evaluate cavity arrangement, molding sequence and component requirements.
• Trial Molding: Initial molded samples are produced to check part formation, material distribution, appearance and structural features.
• Sample Evaluation: Trial parts can be used to verify grip areas, dimensions and compatibility with the corresponding power tool assembly.
• Mold Adjustment: Findings from trial molding can be incorporated into tooling optimization before production approval.
• Reference Mold Life: The demonstrated mold was specified for ≥250,000 shots under appropriate production and maintenance conditions.

5. OEM/ODM Development Capability
• Project-Based Tooling: Mold structure, cavity configuration, steel grade and material combination can be developed according to the client’s specific handle design.
• Power Tool Application Experience: Applicable to handle-development projects for drills, angle grinders and other handheld power tools.
• Professional & DIY Product Programs: Supports tooling development for both professional-grade and DIY power tool product lines.
• Development-to-Production Support: Covers mold engineering, design review, trial molding and production validation for customized power tool components.