Rehman 
Why mould quality decides part quality
Every plastic injection-moulded part is only as good as the mould that made it. Spend less on tooling and you'll fight defects every production run. Spend it right and the same mould runs hundreds of thousands of perfect parts.
Pakistan has a strong tool-making capability — particularly in Gujranwala, where decades of metalworking tradition support precision mould fabrication. Locally-built moulds are typically 40–60% cheaper than imported alternatives, with shorter lead times and easier follow-up support.
Step 1 — Design and DFM review
Mould making starts with your part design. You bring a drawing, 3D file or physical sample. The mould maker reviews it for design for manufacturability (DFM) — checking for things like:
Draft angles on vertical walls (so the part ejects cleanly), uniform wall thickness (to avoid sink marks and warping), parting line placement (so the part comes out without flash), gate location (where molten plastic enters the cavity), ejector pin locations, and any undercuts that need side actions.
Good Pakistani mould makers will suggest small design tweaks at this stage that can dramatically simplify the mould and save you cost. Listen to them — these tweaks rarely affect the part's function and almost always reduce tooling cost.
Step 2 — Mould design
Once the part is DFM-approved, the mould itself is designed: the cavity (the female shape that forms the part's outer surface), the core (the male shape that forms the inner surface), the runner and gate system (how molten plastic flows in), the ejector system (how the finished part is pushed out), and the cooling channels (water lines that quench the steel for faster cycles).
Single-cavity moulds make one part per cycle; multi-cavity moulds make 2, 4, 8 or more. Multi-cavity costs more upfront but pays for itself fast at volume.
Step 3 — Machining the steel
Once designed, the mould is machined from a block of tool steel — usually pre-hardened P20 for production work in Pakistan. CNC milling, lathe (kharad) work, drilling and grinding shape the cavity and core. Final polishing brings the cavity surface to the right finish — mirror polish for glossy parts, satin for matte.
At Rehman Industry this is all done in-house in our Gujranwala workshop — milling, kharad, drilling, grinding, hand-finishing. In-house tooling means short feedback loops on design tweaks and no waiting on outside tool makers.
Step 4 — Sampling (T0, T1, T2)
Before any volume production, the new mould is tested on a moulding machine. The first sample shots (called T0 or T1) are checked against your drawing for dimensions, fit and finish. If anything is off, the mould is tweaked — material is removed (which is easy) or built up (which is harder). Then T2 samples are pulled and checked.
This sampling phase usually takes 1–2 weeks for a normal mould. You sign off on the sample parts before production starts.
Lead times — what to expect
Typical Pakistani mould-making lead times:
Simple single-cavity mould — 3–4 weeks from DFM approval to first sample.
Medium multi-cavity mould — 5–8 weeks.
Complex multi-cavity with side actions — 8–12 weeks.
Add 1–2 weeks for sampling and approval. Add another 1–2 weeks if you need a refurbishment or design change after the first sample.
Cost — what to budget
Tooling cost varies massively by complexity. Realistic Pakistani ranges:
Simple single-cavity production mould — PKR 80,000 to 200,000.
Medium 4-cavity mould — PKR 350,000 to 700,000.
Complex precision mould — PKR 800,000 to several million.
These are for locally-made tooling. Imported moulds are typically 1.8–2.5× the price and take longer to source.
How to choose a Pakistani mould maker
Look for: an in-house workshop (not subcontracting), previous mould samples you can see, willingness to give DFM advice up front (not just take an order), and an honest lead-time and cost estimate without inflated promises.
Avoid: anyone who quotes without seeing your part details, anyone who can't show you a sample of work, and anyone who underbids competitors by 40%+ — that usually means corners will be cut on steel quality or finish.
Why work with us
Rehman Industry has been making moulds in Gujranwala since 2006. Everything happens under one roof: DFM review, mould design, machining (CNC, lathe, drilling, grinding), sampling, and the actual production. That means short feedback loops, faster lead times, and tooling that holds up for the long haul. Send us your part details — we'll quote within a business day.
What we do at Rehman Industry
Need a quote for your part?
Send us your drawing, sample or just a description. We'll reply within a business day with real numbers.
