Should You Transfer Your Plastic Injection Molding Tools to a New Supplier?

Many companies are asking the same question as they plan to migrate their supply chain,  should we move our existing plastic injection molding tools to a new supplier, or is it better to invest in new ones? The answer is yes, you can move your tools, but it’s not always so simple.

On the surface, transferring existing tools may seem like the most cost-effective and efficient option. However, the reality is more complicated. The process involves more than just shipping; it requires evaluating the tool’s condition, ensuring compatibility with the new supplier’s equipment, and accounting for costs related to transport, requalification, and potential downtime. In some cases, opening new tools might be a better long-term solution. 

In this article, we’ll explore the key factors to consider when transferring tools, when it makes sense to invest in new ones, and how to navigate the transition smoothly.

Factors to Consider When Transferring Existing Tools

Moving your existing plastic injection molding tools to a new supplier can be a viable option, but several critical factors must be evaluated to determine whether it’s the right decision. While transferring molds can save money compared to building new ones, the process comes with potential risks and costs that must be carefully managed.

Tool Condition and Compatibility

A story that has come up a few times is a company decides to move its plastic injection molding tools from a supplier in China to a new manufacturer in Asia. The molds have been in use for several years and were maintained regularly. However, upon arrival at the new facility, the new supplier discovers that the cooling lines are designed for a different type of injection molding press, causing inefficiencies in cycle time and part consistency.

Additionally, the tool’s ejector system is incompatible with the new supplier’s machines, requiring modifications before it can function properly. These adjustments add unexpected costs and delays to production, ultimately making the transfer more expensive and time-consuming than anticipated. If the company had conducted a detailed audit before the tooling transfer, they might have determined that investing in a new tool, designed specifically for the new supplier’s equipment, would have been a better long-term solution.

Transfer Costs

Transferring tools involves more than just shipping expenses. The cost of disassembling, crating, transporting, and requalifying the mold must be factored into the overall decision. If a mold requires modifications to fit the new supplier’s machines or undergoes repairs due to damage during transit, these costs can add up quickly. In some cases, the total cost of transfer may approach the price of building a new tool, making it essential to evaluate whether the savings justify the effort.

Downtime and Production Disruptions

Any transition between suppliers carries the risk of production downtime. The mold must be installed, tested, and qualified at the new facility, which can take weeks or even months depending on the complexity of the tool and the required validation process. If the tool needs modifications or repairs, additional delays may occur. Companies should consider whether they can afford this disruption or if it makes more sense to build a new tool while continuing production with the existing supplier during the transition.

Supplier Expertise

Not all contract manufacturers have the same level of expertise in handling transferred molds. A supplier with experience in running and maintaining existing tools can help ensure a smoother transition, reducing the risk of unexpected delays or defects. The new supplier should conduct a thorough evaluation of the tool before accepting it to confirm that it meets their operational requirements. If the supplier lacks the technical expertise to troubleshoot and optimize a transferred mold, quality issues, and inefficiencies could arise.

Considering these factors carefully will help companies determine whether transferring an existing mold is the best option or if building new tools would be a smarter long-term investment.

When It’s Better to Open New Tools

While transferring existing plastic injection molding tools can save time and money in some cases, there are situations where investing in new molds is the smarter long-term decision. Choosing to build new tools with your new supplier can help avoid compatibility issues, reduce production risks, and improve overall manufacturing efficiency. Here are some key scenarios where opening new tools is the better option.

Tool Age and Wear

Injection molds have a certain lifespan, and if a mold is nearing the end of its usable life, transferring it to a new supplier may not be worth the effort. Over time, repeated use can lead to poor performance, resulting in dimensional inconsistencies, increased scrap rates, and more frequent maintenance requirements. If a tool is already showing signs of the end of life, it may be more cost-effective to invest in a new mold rather than spending money on repairs and modifications.

Production Volume and Lifecycle Needs

If a company is planning to scale production or extend the product’s lifecycle, investing in a new mold may provide better long-term value. Older molds may not be optimized for high-volume manufacturing, leading to inefficiencies that increase per-unit costs. Additionally, if demand is expected to remain strong for years to come, designing a new mold improve the yield and efficiency of the tool.

Design Changes and Process Improvements

A supply chain transition is often a good time to evaluate potential design and process improvements. If the existing mold has limitations, creating a new tool allows manufacturers to undergo design for manufacturing (DFM) that improves part quality, reduces cycle times, and minimizes defects. Investing in a new mold can also help integrate new materials or production techniques that weren’t feasible with the original tooling.

While the upfront cost of new tooling is higher, the long-term benefits might outweigh the initial investment. Before making a decision, companies should conduct a full cost-benefit analysis, factoring in mold condition, expected production volumes, and potential process improvements. In many cases, opening new tools sets the foundation for a more stable and scalable manufacturing operation.

The Validation Process for Transferred Tools

If a company transfers existing tools to a new supplier a thorough validation process is essential to ensure consistent quality and production efficiency. This process helps confirm that the tool functions correctly in its new environment, meets the required specifications, and is ready for full-scale manufacturing. The key steps include:

Tool Inspection and Refurbishment

Upon arrival, the supplier inspects the mold for any signs of wear or damage. If necessary, they may perform repairs, replace worn components, or modify the tool to fit their equipment.

Test Runs and Process Optimization

The supplier conducts initial test shots to identify any issues with injection pressure, cooling efficiency, or part ejection. They fine-tune machine settings to optimize cycle times and ensure part consistency. These trials can be similar to when you originally made tools with T0, T1, and T2 stage trials. 

First Article Inspection (FAI) 

The first batch of molded parts undergoes a detailed inspection, checking for dimensional accuracy, surface finish, and material properties. Any deviations from the original specifications must be addressed before moving forward.

Pilot Production and Qualification

A pilot run is conducted to verify that the mold performs consistently over multiple cycles and that the final unit can be assembled correctly by the new supplier. If needed, further adjustments are made before full-scale production begins.

Approval and Documentation 

Once the mold passes qualification, the supplier documents the validated process parameters to ensure repeatability in future production runs.

A well-executed validation process minimizes risks if you’re transferring an existing mold. Companies should work closely with their supplier to ensure clear communication, detailed documentation, and proper testing to avoid costly delays or quality issues. By taking the time to validate tools correctly, manufacturers can achieve a seamless production transition with minimal disruption.

How EPower Can Help Transfer Your Plastic Injection Molding Tools

Transferring plastic injection molding tools to a new supplier is a complex process and we are here to help you through the process. We have the expertise to assess, optimize, and validate your tools, ensuring they run efficiently in our facilities. Whether you're moving production to improve costs, mitigate risks, or diversify your supply chain, we offer you the options so you can choose the right option for you.

With production facilities in both China and Thailand, we offer you multiple production locations based on your needs. Therefore, if you are looking to shift manufacturing from China to another location, we can lead you through the entire process, such as the tool audit, logistics, inspections, modifications, and everything else. Our approach ensures your tools are properly integrated, tested, and ready for production without delays.

EPower Corp controls the entire transfer process from start to finish, eliminating the headaches that come with moving molds between suppliers. We prioritize efficiency, cost savings, and quality, helping you make a smooth transition with confidence. If you're considering transferring your tools, contact us to see how we can support your manufacturing needs.