2ltr Yogurt Project Mould bottle
start to finish
Read about the 2ltr Yogurt Mould.
phase one
Design & Specification
what. why. when. who
1. Determine the Brief
The customer approached us in early 2025 to create a quad cavity blow mould tool for 2-liter yogurt pots made from HDPE plastic. We designed the mould out of stainless steel to be durable and efficient, ensuring it fits perfectly on a Magic blow moulding machine for high-quality, cost-effective production.
the container
2. Design the Bottle
The process begins by designing the container using advanced software such as SolidWorks or PowerShape. This stage focuses on creating a detailed 3D model that meets the customer’s requirements, ensuring precision and functionality for the final result.
final design
3. Approved bottle drawing
Before commencing the mould design, we present the final bottle or container drawing along with a comprehensive specification to the customer. This ensures all details, including dimensions, materials, and design features, meet their expectations. Once the customer provides approval, we move forward with the mould design process, confident that the container design aligns with their requirements.
phase two
tool design
machine details
1.Identify correct machine specifications
The mould design process begins by thoroughly understanding and aligning with the customer’s specific machine details. This step ensures that we accurately assess the machine’s capabilities, space constraints, and operational requirements, laying the foundation for a tailored, efficient mould design that meets both functionality and performance standards.
mould design
2. Final Tool Proposal
After aligning with the customer’s machine details, we proceed with the mould design, carefully considering key factors such as cooling efficiency, weight, material selection, and fixings. Proper cooling is essential for achieving optimal cycle times and consistent part quality. The design also focuses on selecting durable materials and efficient fixings to ensure the mould is robust, easy to maintain, and capable of withstanding the demands of production.
internal checks & sign off
3. Check the mould design
Before a mould is released for production, it undergoes a rigorous internal checking process to ensure precision, durability, and optimal performance. Every critical dimension—including height, width, neck diameter, and thread form—is meticulously verified across multiple stages. Water circuits are inspected to prevent interference with dowels & bushes, while venting, knifing, and engraving are thoroughly assessed. Key components such as the sealing plate, base plate, and neck insert are reviewed for proper alignment and secure engagement. Only after every element meets our stringent quality standards is the mould signed off and approved for production.
phase three
Manufacture
programming
1. Setting-Up the cNC programme
The manufacturing process begins with precise CNC programming using Edgecam (2D), PowerMill, and PowerShape (3D) to ensure accuracy and efficiency. Each component follows a structured workflow, starting with a first operation (first op) focused on roughing out the material and drilling holes. This is followed by a second operation (second op) to refine details and achieve the final specifications.
issue the drawings
2. Issue Drawings & programmes
Once programming is complete, the necessary technical drawings and CNC programmes are issued to the relevant toolmakers. This ensures that each specialist has the exact specifications required to manufacture components to the highest standard.
production
3. Manufacture Mould & Supporting Parts
With programming and tooling in place, production moves to the machining phase, where each component is manufactured using the most suitable process. 5-axis CNC machines handle complex geometries and multi-directional cutting, while 3-axis CNC machines are used for standard shaping and precision finishing. Sparking is employed to create intricate thread profiles and small, detailed shapes that cannot be achieved through conventional milling. Grinding ensures that all critical surfaces meet the required tolerances with a high-quality finish. For blow pins & other turned components, the lathe process is used to achieve precise diameters and smooth surface finishes, ensuring optimal performance in the final mould assembly. This structured approach guarantees a production-ready mould that meets all performance and durability standards.
