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64-Cavity LSR Automotive Wire Harness Seal, 60-Second Fully Automated Production Solution

TYM's horizontal liquid silicone rubber injection molding machine delivered a 64-cavity automotive wire harness seal solution that cuts cycle time to 60 seconds with full automation. This auto parts wiring harness breakthrough reduced labor costs and boosted production capacity for a major tier-one supplier.

Cycle Time

60 seconds

Cavities

64

Output

~92,160 pieces/day (24h operation)

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Core Technology Breakdown

TYM-W5050 Horizontal LSR Injection Molding Machine

The TYM-W5050 horizontal LSR injection molding machine is purpose-built for high-cavitation, high-precision liquid silicone processing of small automotive sealing components. Key capabilities include:

- ▸ Stable, rigid clamping suited to sustained 128-cavity mold operation
- ▸ LSR metering and mixing system with precision injection unit for consistent shot-to-shot repeatability
- ▸ Closed-loop servo control for consistent shot weight across all cavities
- ▸ Designed for 60-second cycle time at full 128-cavity production
- ▸ Integrated temperature control for both mold and injection unit, holding tight process windows for automotive-grade LSR compounds

The machine delivers the clamping stability and injection consistency required for thin-wall, high-cavitation wire seal and connector seal molding.

Cold-Runner Precision Injection Control

By using a single and precisely balanced cold-flow system to supply materials to all 128 cavities, this is of crucial importance for the quality of the automotive wiring harnesses:

- - ▸ Balanced flow distribution ensures even fill across all 128 cavities
  - ▸ Eliminates overfill or short-shot defects common in high-cavitation LSR molds
  - ▸ Precise pressure and temperature control throughout the cold-runner channels
  - ▸ Reduces material waste — no sprue degradation, minimal runner scrap

Result: Every sealing ring is uniform in wall thickness, weight, and hardness — critical for consistent pressure-holding performance.

128-Cavity Cold-Runner Mold

The cold-runner mold is the heart of the system. Our design features:

- ▸ Uniform cooling channel layout across all 128 cavities to keep cycle time stable and repeatable
  - ▸ 128-cavity cold-runner system — no visible gate marks on the finished connector
  - ▸ Proprietary cooling channel layout ensures uniform temperature across all 128 cavities
  - - ▸ Precision-machined cavity inserts for tight dimensional tolerances on critical sealing surfaces

The cold-runner molding process produces IV cannula connectors with clean, flash-free surfaces — ready for downstream assembly or sterilization without secondary deflashing operations.

Automatic Demolding System — Full Automation

A dedicated automatic demolding (extraction) machine completes the automation loop:

- ▸ Automatically extracts all 128 finished parts after mold opening, without manual intervention
  - ▸ Transfers parts to conveyor or collection trays for downstream inspection/packaging
  - ▸ Eliminates manual part removal — no operator exposure to hot mold surfaces
  - ▸ Cycle-synchronized operation — demolding adds no extra time to the 60-second cycle

With the automatic demolding system, the entire production cell runs with minimal human intervention, reducing labor cost and eliminating repetitive manual-picking risk.

Production Detail: A single operator can oversee multiple production cells simultaneously, each producing ~92,160 wire/connector seals per day.

Key Benefits at a Glance

Benefit	Detail
60-Second Cycle	Efficient cycle time for 128-cavity LSR wire harness seal production — 128 pieces every 60 seconds.
Zero-Waste Molding	Cold-runner system = no sprues, no runner scrap. Near-100% material utilization.
Clean, Flash-Free Parts	Precision mold design produces parts ready for use with minimal secondary finishing.
Fully Automated	Automatic demolding + conveyor integration = minimal manual handling. One operator oversees multiple cells.
Consistent Sealing Performance	Uniform cavity design ensures every seal meets tight dimensional tolerances for reliable IP-rated sealing.
Fast Time-to-Market	Complete turnkey solution — machine, mold, automation, and process parameters tuned and validated before shipment.
Lower Labor Cost	Automation reduces manual handling, sorting, and repetitive labor.

Automotive accessory liquid silicone wire harness - TYM

Technical Specifications

Parameter	Specification
Machine Type	TYM-W5050 Horizontal LSR Injection Molding Machine
Injection System	Servo-driven, closed-loop control
Mold Cavities	64 cavities, cold-runner design
Runner Type	Cold-runner, self-cutting sprue-less gates
Cycle Time	60 seconds (64 pieces per cycle)
Daily Output (24h)	~92,160 pieces
Automation	Automatic demolding (extraction) system
Material	Liquid Silicone Rubber (LSR)
Application	Automotive wire harness single-wire seals, connector seals, cable/wire grommets

One Supplier. One System. One Guarantee.

Rather than sourcing the machine, the mold platform, and the insert sets from separate vendors, we deliver the entire catheter production system — machine, shared mold base, and the full set of size-specific inserts — from a single source:

No Integration Headaches:

The machine and mold are designed together to ensure optimal performance and seamless compatibility.

Single-Point Responsibility:

We take full accountability for the overall quality, performance, and after-sales service of the entire system.

Pre-Tested and Validated:

The complete system is rigorously tested, tuned, and validated as a single functioning unit before delivery.

Faster Ramp-Up:

With process parameters already configured, your team can start mass production within days of installation.

Proven in Production

Our 128-cavity LSR automotive wiring harness solution has been put into operation in the production environment and can achieve:

High Yield Rate:

Consistently achieves industry-leading pass rates during both visual and dimensional inspections.

Ultra-Low Weight Variation:

Maintains tight cavity-to-cavity weight consistency, ensuring identical product geometry across all 128 cavities.

Minimal Post-Processing Requirement:

Produces flash-free parts with minimized gate marks, reducing the need for deflashing or gate trimming.

Long-Term Process Stability:

Sprueless cold-runner design maintains stable output without process drift over extended production runs.

Made for Global Standards

CE-Certified Safety

All electrical components and integrated safety systems are fully CE-certified, guaranteeing safe and reliable operation in global manufacturing environments.

FDA & EU Compliant Processing:

Engineered to meet strict hygiene standards, our system is fully capable of processing food-grade and medical-grade LSR materials compliant with FDA and EU regulations.

ISO 9001 Quality Management:

Our entire workflow—from initial R&D and mold design to manufacturing and final testing—is strictly governed by ISO 9001 quality management protocols.

Comprehensive Global Support:

We provide complete English technical documentation, intuitive English PLC interfaces, and highly responsive global technical support for commissioning and troubleshooting.

Frequently Asked Questions

Projects

Can this system handle different wire diameters and seal profiles?

Yes. The mold design can be customized for different wire seal and connector seal geometries, wire-hole diameters, and hardness specifications. Injection parameters are fully programmable for changeovers between products. We recommend dedicated molds per part number for optimal cycle time and quality.

What is the typical ROI period?

ROI period depends on production volume and local labor costs; the combination of 60-second cycle, 64-cavity output, and reduced labor requirement delivers significant per-piece cost reduction compared to lower-cavitation or manual-trim processes.

What training and support do you provide?

We provide on-site training for operators and maintenance technicians, complete documentation (machine manual, mold maintenance guide, process parameters), and remote technical support, with engineers available for on-site commissioning and troubleshooting.

Can existing molds be adapted to this machine?

The TYM-W5050 uses standard mounting patterns and ejector configurations, so existing molds can often be adapted with minor modifications. We provide a free compatibility assessment for any existing mold you wish to run on our system.

Can this solution scale beyond 64 cavities?

Yes. This wire harness seal solution is available in three cavitation tiers to match different volume requirements: 64-cavity molds run on the TYM-W4545, 128-cavity molds run on the TYM-W5050, and 256-cavity molds run on the TYM-W555. All three tiers share the same cold-runner, automatic-demolding process concept, so customers can start with a smaller cavitation count and scale up to a larger machine/mold combination as production volume grows.

Ready to Transform Your Nipple Production?

Contact us today for a free consultation, process analysis, and quotation.

We can provide production simulations, sample molding, and ROI projections tailored to your specific requirements.