Zetford : Your Trusted Partner for High-Quality Plastic Injection Moulds
We specialize in high-precision plastic injection mould manufacturing, custom mould bases, and full-scale component production. Serving automotive, aerospace, medical, electrical, and consumer goods industries across India, the USA, Europe, and worldwide.
At Zetford, we specialize in high-precision plastic injection mold manufacturing for local and global clients. Our state-of-the-art toolroom and advanced engineering capabilities deliver custom, high-tolerance tooling built to withstand demanding production runs across diverse industries.
Driven by precision, we leverage cutting-edge AI tools to optimize mold flow analysis, tool design, and machining workflows—ensuring maximum efficiency, pinpoint accuracy, and faster time-to-market. From initial DFM engineering to multi-cavity tool fabrication, we adapt seamlessly to your exact technical requirements.
Our team of mold experts works directly with you to design and build tooling that maximizes product quality and cycle efficiency. Partner with Zetford for end-to-end mold manufacturing backed by uncompromised quality and expert technical support. Contact us today to start your tooling project.
30-1000
Tons, Moulding Machine
10Ton
Max Mould Weight
30–52 HRC
P20, P20HH & H13 core steel
24 h
Quotation & DFM
Zetford equipped with state-of-the-art CNC VMC Machines, EDM and wire cut machinery, we serve top-tier global and domestic manufacturing hubs with zero-defect quality and short lead times.
- Mold making: auto, hand, single, multi-cavity, 2K, family, insert and unscrewing molds.
- In-house mold bases: C45 / C50 steel, plus DME, HASCO and MEUSBURGER standards.
- Molding production: 30T to 1,000T presses for pilot runs and mass production.
- Mold repair: laser welding, core and cavity repair, ECOs on imported molds.
Key Metrics of Our Mould Making
Our performance is measured by the outcomes customers feel most directly: tooling lifespan, dimensional accuracy, speed from design review to production, and first-time inspection pass rates.
Together, these metrics reflect careful upfront engineering and continuous workflow refinement.
Tool Life Cycles
Machining Accuracy
Lead Time Reduction
Quality Acceptance Rate
Automotive Injection Moulds – Precision for Demanding Applications
Our automotive injection moulds are engineered for high-performance plastic components such as interior trims, dashboards, bumpers, connectors, housings, and under-hood parts.Capabilities: Complex geometries, tight tolerances (±0.02mm), multi-slide actions, unscrewing mechanisms, and insert moulding integration.Features: Balanced hot/cold runner systems, optimized gating for warp-free parts, and IATF 16949-compliant processes.Benefits: Reduced cycle times, excellent surface finish, and long tool life (500,000–1,000,000+ shots).As a trusted automotive injection mould manufacturer in Chennai, we support Tier-1 and OEM suppliers with rapid prototyping to full production tooling.
Single-cavity injection moulds produce one part per cycle, offering straightforward flow control and easier process optimization.
- Ideal For: Medium-volume production, larger/complex parts, or when part design requires focused validation.
- Features: Precise core/cavity alignment, efficient cooling channels, and robust ejection systems.
- Benefits: Lower mould cost than multi-cavity, reduced risk of imbalance issues, and high part consistency.
Perfect for transitioning from prototypes to production on small to medium tonnage presses.
Multi-cavity injection moulds feature multiple identical cavities (4, 8, 16, 32+), enabling simultaneous production of several parts per shot for maximum throughput.
- Advantages: Significantly lower cost per part, higher output on the same machine, and balanced runner/gating for uniform filling.
- Our Expertise: Flow analysis simulation, precise cavity balancing, and hot-runner integration to eliminate waste.
- Applications: High-volume automotive fasteners, consumer electronics casings, medical disposables, and packaging components.
As experts in multi-cavity mould manufacturing Chennai, we deliver tools that run reliably on high-tonnage machines for mass production.
Core Engineering & Tooling Capabilities
Mold Design & DFM
Moldflow simulation, gate placement, and conformal cooling design to minimize cycle time and warpage. We catch fill issues and manufacturability risks before any steel is cut.
Precision Mold Fabrication
Multi-cavity tooling, hot runner systems, two-shot (2K) and overmolding, built from hardened tool steel for repeatable dimensions across the full tool life.
Toolroom Machinery
High-speed 5-axis CNC, wire & sinker EDM, surface grinders, and in-house CMMs for closed-loop manufacturing accuracy.
Mold Maintenance & Repair
Lifecycle tracking, refurbishment, spare insert production, and rapid-response repair to minimize downtime at OEM presses.
Why choose us for
Plastic Injection Moulds
Advanced Tooling Infrastructure
CNC, EDM, CMM, and in-house trial presses for complete design-to-tryout under one roof.
Quality & Durability
Hardened steels, PVD coatings, rigorous trials, and detailed reports for zero-defect starts.
Full Range Support
From hand moulds on small tonnage to high-tonnage multi-cavity automotive tools.
Competitive Edge
Cost-optimized designs, reduced material waste, and pan-India supply network.
Our Engineering Workflow
Every tooling project follows a structured workflow from concept to production
1) Concept & Feasibility Review
Define requirements, materials, and volumes.
2) Design & Simulation
CAD modeling and Moldflow analysis.
3) Toolmaking
CNC machining, EDM, and finishing.
4) Sampling & Validation
T1 trials and first article inspection.
5) Production Handoff
PPAP documentation and ongoing support.
Automotive Industry
Tier-1 & Tier-2 automotive interior, exterior, and under-the-hood systems built to IATF 16949 specs.
- Instrument clusters & Dashboards
- HVAC vents & Duct components
- Engine bay sealed connectors
- Headlamp & Tail-light housings
End-Market Expertise
Engineered for Demanding Global Sectors
We engineer precision plastic molds customized to the strict regulatory, thermal, and mechanical demands of critical industries.
Aerospace & Defense
High-strength, lightweight engineering polymers for high-altitude resilience.
- Aircraft seating & cabin trims
- Avionics junction enclosures
- Lightweight structural ducting
- Radome & sensor protection covers
Medical & Healthcare
Cleanroom-compatible tooling engineered with mirror-finish stainless steel (S136/Stavax).
- Surgical instrument housings
- Dialysis & fluidic manifolds
- Diagnostic cassette bodies
- Syringe barrels & luer fittings
Electrical & Electronics
Flame retardant (UL94 V-0) high-dielectric tooling with tight pin-pitch tolerances.
- Circuit breaker (MCB) enclosures
- Terminal blocks & relay sockets
- DIN rail mounting clips
- Smart meter base and bezel
Consumer Goods & Appliances
Aesthetic Class-A surface finish molds with complex parting lines and snap-fit features.
- Washing machine control consoles
- Refrigerator internal liners & shelves
- Power tool housings & grips
- Water purifier filter canisters
Telecommunications
UV-stabilized, IP67-rated waterproof enclosures designed for 5G and fiber network hardware.
- Fiber optic distribution hubs
- Outdoor 5G transceiver shells
- Modem & Wi-Fi router enclosures
- Waterproof cable gland caps
Industrial, Agriculture & Fluid Handling
Heavy-wall, abrasion-resistant polymer tooling built for demanding chemical, irrigation, and material-handling applications.
- High-pressure drip irrigation emitters
- Industrial pump impellers & volutes
- Heavy-duty stackable transport crates
- Ball valve bodies & pipe fittings
Quality Control & Inspection Standards
Zetford operates under ISO 9001-aligned procedures with documented work instructions, in-process checkpoints, and statistical process controls. Every tooling project includes First Article Inspection (FAI) documentation and scientific molding trials to lock process windows.
In-Process CMM
Dimension validation at key build stages to catch deviations early.
FAI & Reports
Inspection reports and SPC charts provided with delivery, documenting conformance to drawing specifications.
Scientific Molding
Controlled trials that define a robust, stable processing window.
Thin-Wall Electronics Housing
Consistent 0.8mm wall thickness with uniform cavity fill and tight dimensional tolerances from the first shot. Gate and cooling optimization cut cycle time by 18%.
Medical Diagnostic Components
Validated to sub-0.01mm feature tolerances with statistical process control. Complete FAI reports and full material traceability support regulated audits.
Multi-Cavity Automotive Tooling
An 8-cavity hot-runner tool with matched cavity balance for consistent part quality. Long-run stability exceeds 1 million cycles.
Technical Case Highlights
Consumer Product Part
High-cosmetic Class-A surface finishes with zero sink marks or visual defects. Optimized snap-fit features and mold flow analysis ensured high impact strength, distortion-free geometry, and seamless automated assembly.
Ready to launch your tooling project?
Request a fast, detailed quote or speak with our tooling engineers. We respond to RFQs within 24 hours and provide a dedicated engineering contact to move your project from concept to confirmed scope.