We have our own technological facilities for the manufacturing of injection molds.
We perform product design and 3D modeling in-house.
We do not outsource any stage of the production process to external companies.
Full process control allows us to optimize lead times and project costs.
Injection molds are built exclusively for serial production carried out at SIGERN.
This allows us to offer a complete production implementation process – from part design and 3D modeling, through mold manufacturing, to serial plastic injection molding or aluminum component production. This approach ensures the highest quality and long service life of the mold, since all maintenance, adjustments and repairs are handled in our in-house tooling department, without delays and without transporting the tool outside the facility.
We invite companies that expect professional, stable and responsible production support — with guaranteed quality, reliable delivery and full commitment.
Injection molds are a key element of stable serial production. Their design, manufacturing precision and durability directly influence the quality of molded parts, cycle time and unit cost. Mold design is carried out with consideration of part geometry, material type and the expected production volume. This ensures predictable and repeatable tool performance, reducing the need for corrections during production.
We design and manufacture injection molds tailored to different production requirements, including:
Each mold is designed individually, with a strong focus on process stability and long tool life.
The mold development process is based on clearly defined stages, ensuring full control over both quality and delivery timelines.
This approach allows the mold to reach reach stable operating parameters quickly and helps avoid unplanned production downtime.
Injection molds are designed for long-term, stable operation. The selection of tool materials, cooling systems and guiding components takes into account the requirements of serial production.
Our in-house tooling department enables:
Combining mold design and manufacturing with component production within one organization allows real operating conditions to be considered already at the design stage. Injection parameters and mold geometry are optimized in parallel, which shortens the time required to launch and stabilize production.
For many years, we have been delivering projects in plastic injection molding and injection mold manufacturing for a wide range of technical industries. We also undertake complex and unconventional projects, including solutions protected by patents. Our design and manufacturing experience enables us to implement components that require high precision, durability and repeatability.
We deliver components that meet strict quality and functional requirements, in compliance with the standards applicable in the client’s industry. Our reliability is confirmed by references from our clients that have entrusted us with both serial production and new product implementations — from design to the finished component.
All stages — mold design, tool manufacturing, injection molding and finishing — are carried out at our facility in Poland. This gives us full control over quality, shortens implementation time and ensures stable deliveries. Clients can follow the entire product development and production process in one place.
We invest in automation and precision machining technologies. Our tooling department is equipped with modern CNC machining centers, EDM machines and equipment for precision finishing of injection molds. Serial production is carried out on energy-efficient injection molding machines with robots and automated systems for material feeding and drying, ensuring high mold quality and long service life.
We operate a tooling department specialized in the production of injection molds and their key components, including inserts, sliders and tooling elements. The core of the process is CNC machining, which ensures high precision, repeatability and full compliance with technical documentation — essential for serial production.
We use CNC milling and turning, drilling, grinding and EDM (electrical discharge machining), which enables the production of precise cavities, sharp angles and components with complex geometry, including hardened tool steel. The combination of CNC and EDM technologies allows us to achieve accuracy down to hundredths of a millimeter.
Machining affects not only geometry but also surface quality, tool durability and the stability of the mold during the injection molding process. Each stage is preceded by an analysis of the material, tolerances and design requirements, allowing us to select machining parameters that ensure mold components are perfectly matched to future serial production.
→ CNC and EDM machining in our tooling department is performed exclusively for the production of injection molds intended for further serial production of plastic or aluminum components at SIGERN. We do not accept subcontract machining orders or produce individual custom parts as a standalone service.
CNC and EDM machining in our tooling department is carried out exclusively for the production of injection molds intended for further serial production of plastic or aluminum components at SIGERN. We do not accept subcontract machining orders or produce individual custom parts as a standalone service.
Injection molds for plastics are the foundation of stable and repeatable serial production.
Clients looking for a reliable supplier expect above all: short lead times, predictable costs, long mold life and a secure injection molding process.
SIGERN designs and manufactures injection molds in its own tooling department, which allows us to maintain full control over quality, servicing and delivery timelines, while avoiding subcontractors — and therefore minimizing the risk of delays.
We design injection molds for a specific component, material and production volume. This means we select the number of cavities, durability class, cooling system and runner technology (cold or hot runner) to achieve the shortest possible cycle time and the lowest unit cost of the component.
The injection molding process itself typically takes place at plastic temperatures of 180–350°C and injection pressures reaching up to 1000 bar. For this reason, molds are manufactured from specialized tool steels with increased strength, designed to withstand both thermal and mechanical loads.
At SIGERN, we have developed a cooperation model that ensures full control over manufacturing quality, fast servicing without production downtime, stable deliveries and predictable production cycles, as well as optimization of the tooling for real operating conditions in the foundry.
We design aluminum die casting molds to minimize erosion, microcracking and the soldering effect, ensuring maximum tool life and dimensional stability of the cast components.
For the client, the most important questions are:
✔ Will the mold withstand the planned casting volume?
✔ Will the components remain dimensionally stable at high filling speeds?
✔ How quickly will the supplier respond if mold repair is required?
Aluminum die casting molds (HPDC – High Pressure Die Casting) are among the most heavily loaded production tools. They must withstand the high temperatures of molten metal (630–720°C), rapid thermal changes and significant mechanical loads during the casting cycle.
During the process, the mold typically operates within a temperature range of 180–500°C, while injection pressure in the chamber can reach 300–1200 bar, and locally in the final stage of injection even over 2000 bar. Filling speeds may reach up to 120 m/s, which leads to intense thermal fatigue, microcracking (heat checking) and surface erosion. For this reason, the service life of HPDC molds is naturally shorter than that of plastic injection molds.
Key factors in HPDC mold design include the selection of materials resistant to thermal fatigue, a precisely designed cooling and venting system, geometry that prevents soldering (adhesion of aluminum to steel), design solutions that reduce the risk of mold cracking, appropriate surface finishing, and overall mold optimization for both cycle time and tool durability.
At SIGERN, we have developed a cooperation model that ensures full control over manufacturing quality, fast servicing without production downtime, stable deliveries and predictable production cycles, as well as optimization of the tooling for real operating conditions in the foundry.
We design aluminum die casting molds to minimize erosion, microcracking and the soldering effect, ensuring maximum tool life and dimensional stability of the cast components.
For the client, the most important questions are:
✔ Will the mold withstand the planned casting volume?
✔ Will the components remain dimensionally stable at high filling speeds?
✔ How quickly will the supplier respond if mold repair is required?
The lead time for manufacturing an injection mold depends on the complexity of the component, the number of sliders, types of inserts and the required tolerances. Standard projects are usually completed within 5–14 weeks, while more advanced molds require an individual schedule. The delivery time is provided after analyzing the documentation – always realistic and taking into account the subsequent mold start-up in the injection molding process.
Yes, most clients choose a complete solution: injection mold + serial injection molding. This approach helps avoid issues between the mold manufacturer and the injection molding facility and shortens the time needed to bring the component into production. The mold is designed from the beginning for the target technological process. At SIGERN, this is exactly the cooperation model we offer — manufacturing the mold for the client is always combined with the production of components at our facility.
To prepare a quotation, we require:
Based on this information, we determine the mold design and select the optimal cost solution.
This is not a problem. Based on the supplied component, we perform an analysis and recreate the technical documentation, and then prepare a design suitable for serial production. The client receives a finished plastic component adapted for stable and repeatable deliveries. Our equipment includes a reverse engineering scanner, which allows us to precisely recreate any component.
Yes. We design and manufacture molds in accordance with the requirements of different industries. The components and materials used are selected to meet the client’s specifications and applicable quality standards.
Yes. We accept customer-owned molds and carry out production using them. We perform a technical audit, trial runs and any necessary adjustments before serial production begins. Molds stored at our facility are kept in production-ready condition.
Depending on project requirements, we use different tool steels for mold production. For plastic injection molding, we typically use materials with enhanced strength properties, such as steels 1.2311, 1.2738 and 1.1730, and in some cases selected aluminum alloys.
For aluminum die casting molds, where higher temperature resistance is required (operating temperatures around 600–650°C), we use hot-work tool steels such as WCL, WCLV and WNLV.
Yes, we use Moldflow simulations in our projects to analyze the injection molding process before the mold is manufactured. This allows us to eliminate potential issues at an early stage and prepare the component for safe serial production.
Simulations help optimize part geometry, gate placement and process parameters. As a result, we achieve higher component quality, shorter production start-up time, lower risk of mold modifications and reduced unit costs in long-term deliveries of plastic components.
After the mold is completed, we carry out trials at our injection molding facility. We set the technological parameters and perform trial injections, adjusting and optimizing the process until the molded parts reach the required quality. As a result, the client receives a finished component and assurance that the mold is ready for serial production.
Material selection depends on the function of the final component, the conditions in which it will be used (temperature, loads, chemical exposure) and the desired aesthetics. The client does not need to be an expert in plastics — based on the component’s application, we recommend proven materials and conduct trials to ensure the final product meets both quality and cost requirements.
The lifetime of an injection mold is tailored to the planned production scale. Molds can be designed for both short production runs and high-volume manufacturing counted in hundreds of thousands or even millions of cycles. Already at the quotation stage, we select the most cost-effective solution based on the expected production volume.
Thanks to precise CNC machining, depending on the project requirements, we are able to maintain cavity dimensional tolerances of up to 0.01 mm. This is particularly important for technical and precision components, where the highest dimensional accuracy is required.
During the period of production cooperation (injection molding services carried out at our facility), we provide a warranty for the injection molds manufactured by us. We keep the molds ready for production and carry out any necessary repairs. The client receives assurance of stable production of plastic components as well as the possibility of further support, servicing and potential mold modifications.
We provide full service support for injection molds during the production of components at our facility. In the event of failure or natural wear, we respond quickly by carrying out repairs and maintenance to minimize downtime and maintain continuous supply of plastic components. We do not rely on external service providers for this.
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