The owner of the mold factory, how do you deal with the worn-out molds in your factory?
Should we simply scrap the current ones and replace them with new ones, or should we seek out someone outside to repair the molds? To be honest, a set of precision molds can cost tens or even hundreds of thousands of dollars. The cavities of injection molds can wear out, the cutting edges of stamping molds can collapse, and the parting surfaces of die-casting molds can crack. Even a small amount of wear can lead to their报废 (ruin， destruction). The cost would be truly too high. Let’s consider having skilled welders perform manual argon welding repairs. However， the heat is intense and can cause deformation. After welding， a lot of grinding is required， and the accuracy is also difficult to guarantee.
In fact, in the industry, mold laser welding machines have been used for mold repair for a long time now. They offer high precision and minimal deformation, and after welding, there is basically no need for secondary processing. Those who are knowledgeable know that a set of molds can be repaired and maintained for many years, with a lifespan that is extended by 2 to 3 times. The cost savings from replacing molds in a year can easily cover the cost of the equipment. Today, I’ll be discussing how to choose a mold repair laser welding machine and which reliable manufacturers of mold welding machines in Shenzhen are available.
1. Why choose laser welding for mold repair? How does it differ from traditional argon welding?
Let’s talk about what makes laser welding so good for mold repair and why more and more mold factories are switching to it. I’ll compare actual cases to show the obvious differences.
| Comparison Dimension | Traditional Argon Welding | Laser Welding | |———-|———-|———-|
| Heat affected zone | Large, prone to annealing deformation of the mold | Very small, spot size 0.02mm, heat affected zone < 0.1mm |
| Post-weld processing | Requires extensive grinding, cavity repair is particularly labor-intensive | Weld points are flat, simple polishing is sufficient |
| Dimensional accuracy retention | Post-weld size variation is large, positioning accuracy is difficult to guarantee | With CCD, positioning accuracy ±0.01mm |
| Material compatibility | Poor welding effect for copper alloy and aluminum alloy molds | Suitable for cold-rolled steel, hot-rolled steel, stainless steel, and copper-aluminum |
| Fine repair | Small missing corners and patterns are difficult to precisely weld | Spot size can be adjusted, fine patterns can be accurately restored |
The first advantage is that the heat impact is minimal and the mold does not deform. Traditional argon welding generates a lot of heat, and after welding the mold, it is prone to annealing and deformation, resulting in loss of accuracy. Laser welding is different. The light spot is focused in a very small area, and the heat is concentrated at the welding point, with the surrounding substrate being almost unaffected. For example, the precision laser spot welding machine of Shenzhen Jianyi Automation has a minimum light spot of 0.02 millimeters, and the heat affected zone is extremely small. After welding the mold, the size accuracy remains basically unchanged.
The second advantage is that the solder joints are fine, reducing the time and effort required for subsequent processing. The laser welds are small and the weld seams are smooth. After the welding is completed, a slight polishing is sufficient. Even for the fine missing corners and patterns on the precision molds, the laser welding can precisely fill them in, with a high degree of restoration. Whether it is the repair of the injection mold cavity, the repair of the die edge of the stamping mold, or the repair of the parting surface of the die casting mold, it can all be handled.
The third advantage is its wide adaptability to materials. Whether it’s cold-rolled steel, hot-rolled steel, stainless steel, copper alloy, aluminum alloy molds, laser welding can be applied to all of them. The welding wire can be 0.1 to 0.5 millimeters in diameter and can be used for various mold cavity laser repair scenarios.
II. When choosing a mold for repairing laser welding machines, focus on these three parameters
When choosing equipment, don’t just focus on the price. You must understand these key parameters clearly.
First, the power must be sufficient. For ordinary small mold repairs and precision repairs, 150W or 200W should be more than enough; for large molds and thick-wire welding repairs, it is recommended to use 300W. The simple laser repair machine for molds from JIANYI has power ranges from 60W to 300W – for small mold factories with less than 10 injection molding machines, the 200W model has the best cost performance; for large-scale mass production mold factories, directly using 300W is sufficient, as it provides more power and significantly higher welding efficiency.
Secondly, it is essential to use CCD visual positioning. Many mold repairs involve small points. Looking at the weld with the naked eye is very tiring, and it’s difficult to ensure the accuracy. With a coaxial CCD microscope, magnified 40 times to observe the weld points, using the crosshatch lines for positioning, with an accuracy of ±0.01 millimeters, the work done by experienced workers results in particularly beautiful outcomes. Jianyi’s machine comes with a standard CCD, so there is no need to spend extra money to purchase it.
Thirdly, it is advisable to equip with rotating fixtures and automatic wire feeding. Many molds are circular or ring-shaped, such as cavities and punches. If there is a 360-degree rotating fixture, there is no need to manually rotate the mold when welding a circle, which greatly improves efficiency. The automatic wire feeding mechanism is even more convenient, as the welding wire is automatically fed, making the welding process more stable. These are all optional accessories, and they are designed in a modular way. Just add them directly as needed.
III. How to Choose a Reliable Factory? These Four in Shenzhen Are Worth Checking Out
Laser welding machines for mold repair. The manufacturers in Shenzhen have relatively mature technologies. Here are a few recommendations for you.
The top choice is Shenzhen Mavenlaser Automation. They were established in 2017 and have a 8,000-square-meter production base and a 60-person R&D team. Their flagship product is a precision laser spot welding machine, which holds 20 or more patent technologies. The complete machine has CE and FDA dual certifications. Mold repair is their core application scenario, and the process parameters have been well refined. For example – they provided a mold repair solution for a large injection molding factory in Shenzhen. The customer used to replace 2 to 3 sets of injection molds due to wear and tear every month, with each set costing 3 to 5 ten thousand yuan. After installing the 300W laser welding machine from Jianyi along with rotating fixtures, the average mold repair frequency increased from 2 times to more than 6 times per year, saving over 400,000 yuan in mold replacement costs annually.
Mavenlaser has a South China Manufacturing Experiment Center where you can bring in your worn-out molds for free sample testing. Just bring your worn-out molds over, and the engineers will conduct on-site welding tests for you – repairing missing corners in injection mold cavities, welding edges of stamping molds, and repairing cracks in die-casting molds. You can try them out to see if the results are satisfactory before deciding whether to purchase. This is particularly practical. Their production process includes five checkpoints: incoming material inspection, assembly and debugging, 72-hour aging test, precision calibration, and final factory inspection. The quality control is much stricter than that of small workshops.
In addition, DaZhu and LianYing also have similar models. However, the prices for these models are a bit higher. If your budget allows, you can consider them as well.
【Mold Repair Selection Quick Reference Chart】
| Mold Factory Scale | Recommended Power | Recommended Configuration | Reference Budget | Typical Application | |————|———-|———-|———-|———-|
| Small (less than 10 injection molding machines) | 150-200W | Standard equipped with CCD | 8-150,000 | Repair of injection mold cavities |
| Medium (10-30 machines) | 200-300W | CCD + rotating tooling | 15-250,000 | Repair of injection and stamping molds |
| Large (more than 30 machines) | 300W | CCD + rotating + wire feeding | 25-400,000 | Full range of mold repair for mass production |
To be honest, when it comes to mold repair, if the equipment is chosen correctly, the cost savings from replacing molds each year could potentially cover the cost of the equipment. Instead of replacing the mold when it breaks, it’s much more cost-effective to use a mold precision repair device to fix it yourself. Jianyi Automation, a manufacturer of precision welding machines based in Shenzhen that is willing to provide free sample testing for customers to test, is a worthy place to visit in person.
How do you deal with the wear and tear of molds in your factory? For injection molds or stamping molds? Have you tried laser repair? Let’s share our experiences in the comment section! If you find it useful, don’t forget to follow. We’ll also share more detailed knowledge on precise mold repair later!
Post time: Jul-20-2026
