Mould repair and die remanufacturing

Mold Repair and Restoration

After a certain number of cycles, a mold inevitably requires replacement of either its moving components or form-shaping elements (punch, die).

Over the years of working in the market, we have received numerous requests and helped clients restore and refurbish molds of various types and with varying degrees of damage. Among our "patients" were both cold and hot runner molds, as well as blow molds, punches, and dies.

In 2022, due to the war, we started receiving requests from clients with molds damaged by fire (at temperatures exceeding 500°C). We successfully restored these molds, replaced hot runner systems, heaters, and components, and restarted them within one month.

Causes of Mold Failure

• Wear of form-shaping components under high load
• Improper storage and cleaning
• Mechanical damage
• Corrosion and carbon deposits
• Effects of extreme temperatures
• Distortion or jamming of elements due to friction
• Defects caused by plastic sticking

To avoid downtime, mold diagnostics and repair must be performed promptly. Regular technical inspections help identify critical damage before it leads to complete production shutdown.

Workflow

Stage 1 — Diagnostics

1. The mold is delivered to our production site
2. We perform a technical inspection
3. Prepare a diagnostics report
4. Determine the scope of work and cost
5. Finalize the estimate with the client

Stage 2 — Tooling Repair

• Milling, turning, grinding, polishing operations
• Crack and chip welding using MICROSPOT equipment
• Restoration of form-shaping surfaces
• Replacement of damaged elements or components

Tooling and Mold Assembly Repairs

• Restoration of units and guides
• Precision recovery of seating geometry
• Adjustment and testing of mechanical functionality

Old Die Restoration

1. Restoring the working surface
2. Eliminating defects using micro welding
3. Dimension control after processing
4. Adaptation to updated technological tooling

Testing and Launch

• Testing the mold on our injection molding machines
• Producing a test batch for quality control
• Providing further usage recommendations
• If defects are found, the mold is returned for rework at no extra cost

Additional Services

1. Wear and damage analysis, assessing restoration feasibility via component replacement
2. Removal of corrosion, carbon, and dirt, followed by conservation using Ambersil lubricants (such as Rust flash, Green Mould Protective)
3. Restoration of form-shaping surfaces
4. Welding cracks, chips, and other damage while preserving material hardness in an inert gas environment using MICROSPOT
5. Testing restored and refurbished molds on our equipment. All test-produced items are transferred to the client and remain their property

Benefits of Working with KVOTA

• Over 30 years of experience in mold manufacturing and restoration
• In-house tooling department and equipment
• Components available in stock (Ternopil) — fast turnaround
• Clear estimates and step-by-step control
• Complete support — from diagnostics to restart
• Option to decline repair if the mold is not the issue

If you require restoration of old dies, tooling repair, or comprehensive diagnostics and mold repair, KVOTA delivers a full technical cycle — on time, on budget, and with quality.