Mold Design
Full 3D mold design with cooling layout, gating strategy and ejection concept developed against the moldflow model, not after it.
HKR Tool Shop
The specialist division where Rea Automotive's tooling is designed, cut, qualified and proven. Part of the company since 2006 — and the reason a design change here becomes a validated part in weeks rather than quarters.
DISCIPLINES
What HKR Does
Six disciplines under one roof, sequenced so a mold never waits on an outside supplier mid-build.
High-Speed Machining
5-axis machining to 42,000 RPM producing near-final surface finish, minimising the hand polishing that introduces variation.
Wire & Sinker EDM
Electrical discharge machining to ±2 μm for the sharp internal geometry and fine detail that cutters physically cannot reach.
Progressive Dies
Multi-station progressive stamping dies for metal inserts and carriers, built to the same tolerance discipline as our molds.
Tryout & Qualification
Dedicated tryout presses run the tool in production material, producing first articles and a capability study before handover.
Maintenance & Repair
Scheduled servicing, engineering changes and emergency repair — on tools we built and on tools you inherited from elsewhere.
ENVELOPE
Tool Classes We Build
Indicative build envelope. Anything outside these ranges is worth a conversation rather than an assumption.
| Tool Class | Cavitation | Max Tool Weight | Tolerance | Typical Lead Time |
|---|---|---|---|---|
| Prototype / Bridge Mold | 1 – 2 cavity | 1.5 t | ± 50 μm | 3 – 5 wks |
| Single-Face Production Mold | 1 – 8 cavity | 8 t | ± 15 μm | 10 – 14 wks |
| High-Cavitation Mold | 8 – 64 cavity | 12 t | ± 10 μm | 14 – 20 wks |
| Multi-Component (2K / 3K) | 2 – 16 cavity | 14 t | ± 10 μm | 16 – 22 wks |
| Insert / Overmold Tool | 1 – 16 cavity | 9 t | ± 12 μm | 12 – 18 wks |
| Progressive Stamping Die | Up to 18 stations | 6 t | ± 5 μm | 12 – 18 wks |
TOOL BUILD
From Model To Qualified Mold
Indicative timeline for a single-face production mold. Every gate produces a document you receive, not just an internal sign-off.
Design & Simulation
Mold design frozen against moldflow, cooling and warpage analysis. DFM report issued.
Steel Procurement
Tool steel ordered, certified and pre-machined. Hardness and cleanliness verified on receipt.
Machining & EDM
5-axis roughing and finishing, wire and sinker EDM for detail geometry, then surface treatment.
Assembly & Fitting
Bench assembly, shut-off fitting, hot runner installation and full function check.
Tryout & Handover
Tryout in production material, dimensional report, capability study and documented handover.
THE ARGUMENT
Why Tooling Stays In-House
The industry spent two decades outsourcing toolmaking to the lowest bidder. We went the other way, and the numbers are the reason: when the people who cut the steel sit forty metres from the presses that run it, problems get solved in hours instead of shipping containers.
These are our own averages across programs launched since 2020, measured against the same work quoted through external tool sources.
See The Full Process
Engineering change turnaround
4 days vs 5 weeks
Tryout-to-approval iterations
2.1 avg vs 4.6
Program launch slippage
− 68 %
Unplanned tool downtime
< 0.9 %
Mold life vs contracted shots
+ 22 % typical
TOOLING ENQUIRY
Need A Mold Built?
Send a 3D model, target cavitation and annual volume. We will come back with a build concept, a lead time, and the risks we can see from here.