Injection Moulding

BÖHLER M200 is a prehardened, non-corrosion-resistant chromium-manganese-molybdenum alloyed plastic mould steel with very good machinability and uniform strength over the entire cross-section of medium-sized dimensions.

BÖHLER M238 is a prehardened, non-corrosion-resistant plastic mould steel with good machinability. The addition of Ni guarantees uniform strength across the entire cross-section, even with large dimensions (up to 600 mm).

BÖHLER M789 AMPO is a newly developed maraging steel, which combines the mechanical properties of 1.2709 with the corrosion resistance of 17-4PH. This patent bending grade can easily printed without any preheating and achieves a hardness of about 52 HRC with a very easy heat treatment. Furthermore, this material shows an excellent polishability, which makes it the ideal choice for inserts with conformal cooling in plastic injection molding and in any other application where a high hardness and corrosion resistance is of need.

BÖHLER N700 is a martensitic, corrosion-resistant, precipitation-hardenable chromium-nickel-copper steel with high strength and toughness. Further increases in strength can be achieved by cold forming and subsequent precipitation hardening. These products are typically used for parts that require higher corrosion resistance than the usual 13% or 17% chromium steels and high strength. Various remelting processes are used to improve steel purity and homogeneity. (ESR, PESR, VAR). Certain processing methods and operating conditions can make these products susceptible to stress corrosion cracking. For applications such as bolting where stress corrosion cracking is possible, the product should be aged for at least 4 hours at the highest temperature compatible with the strength requirements, but in no case lower than 552 °C. Typical engineering applications include surgical and dental instruments as well as aerospace components, reactor construction, highly stressed pump parts, springs and ship shafts.

BÖHLER W302 ISOBLOC is a 5% chromium steel and corresponds to material number 1.2344 (X40CrMoV5-1). Produced via the electroslag remelting process (ESR), this tool steel has very high hot toughness as well as very high hot hardness and a very good resistance against heat-checkings. The combination of these properties makes it a top performer in closed- and open-die forging as well as in high- and low-pressure die casting. In addition, this material has very good polishability and is therefore also often used as a molding material for plastic injection molds.

BÖHLER W302 ISODISC is a 5% chromium steel and corresponds to material number 1.2344 (X40CrMoV5-1). This common tool steel has good hot toughness as well as a high hot hardness and a high resistance against heat-checkings. The combination of these properties makes it a standard choice in extrusion, forging and low-pressure die casting. This material is also available as W302 ISOBLOC which is a remelted grade with improved cleanliness, homogeneity and toughness.

The BÖHLER W360 AMPO is the powder equivalent of the W360 ISOBLOC. Due to its chemical composition, the material belongs to the product group of hot-work tool steels. After hardening and tempering, it can achieve a hardness of up to 57 HRC with very good toughness properties. Its high temperature wear resistance, heat resistance and toughness characterizes the material. Applications: Printed components with conformal cooling for die casting applications, wear protection layers and repair work in mold making using laser cladding.

BÖHLER W360 ISOBLOC is a material produced by the electroslag remelting process (ESR), which has been specially adapted for use at high tool hardnesses in the range of 51-57 HRC. Although the steel can be classified as a 5% chromium steel, the increased carbon and molybdenum content coupled with state-of-the-art manufacturing technology ensures that BÖHLER W360 ISOBLOC still shows a very good toughness and an exceptionally good thermal resistance, even at high hardness levels. These properties make the steel the perfect choice for smaller components in the die casting sector (e.g., mold inserts, cores, core pins, ejector pins, etc.). The material also is frequently the preferred choice for closed-die and open-die forging tools due to its high wear resistance. Because of this excellent wear resistance and the high toughness, BÖHLER W360 ISOBLOC is also frequently used for cold work applications and as a molding material for plastic injection molds. The Steel also is available as powder material for metal-3D-printing under the brand name BÖHLER W360 AMPO.

BÖHLER W403 VMR is a vacuum remelted material which was developed as a problem solver for tools for where a standard solution is no longer sufficient. The steel can be assigned to the 5% chromium steels and has a very high purity due to the special manufacturing technology. In addition, the increased molybdenum content leads to improved thermal resistance as well as wear resistance, which makes BÖHLER W403 VMR an all-rounder that is often used for highly stressed dies in the die casting sector. In addition, Böhler W403 VMR has outstanding polishability. For this reason, the steel is also popular as a molding material for plastic injection molds.

Uddeholm Corrax is a precipitation hardening steel with a unique set of properties that makes it perfect for many demanding applications. The superior resistance against corrosion combined with a hardness up to 50 HRC and a simple heat treatment makes Uddeholm Corrax the obvious choice for long run series of aggressive plastics such as PVC. The chemical composition makes Uddeholm Corrax easy to process by Additive Manufacturing. Hence, it is also available as powder for Laser Powder Bed Fusion (LPBF) and Laser Metal Deposition (LMD). Benefits Very good corrosion resistance Flexible hardness of 34-50 HRC achieved by ageing No hard “white layer” after EDM

Uddeholm Mirrax ESR is a through hardening corrosion resistant steel with very good polishability. Mainly intended for medium to large cross sections. It has a unique combination of toughness, corrosion resistance and through hardening properties. Benefits Low mould maintenance costs: The surface of cavity impressions retain their original finish over extended running periods. Moulds stored or operated in humid conditions require less protection. Low production costs: Water cooling channels are less affected by corrosion Heat transfer characteristics, and therefore cooling efficiency, are constant throughout the mould life, ensuring consistent cycle times. Safe mould use because of good toughness also in big dimensions

Uddeholm Orvar Supreme can be regarded as an “all-round” steel used in several application areas. Except for hot work application areas the steel is also used in moulds for plastics and as a material in high stressed axles. The high degree of purity and the very fine structure shows improvement in dies and components where high mechanical and thermal stresses are involved. Uddeholm Orvar Supreme is produced using the Electro-Slag-Refining (ESR) technique. The ESR process gives Uddeholm Orvar Supreme a high level of homogeneity and cleanliness which results in a high performance hot work tool steel of the highest quality. Benefits Improved tooling performance Uddeholm Orvar Supreme meets the North American Die Casting Association (NADCA) #207 requirements for Superior high quality H-13 die steel. Standard specification W.nr 1.2344 / AISI H13 / AFNOR Z38 CDV 5.1

Uddeholm Rigor is a medium alloyed tool steel with a good resistance to both the abrasive and adhesive types of wear as well as good resistance to cracking. This combination makes Uddeholm Rigor an all purpose tool steel for medium run cold work applications. Short tool making lead times Safe and consistent production Good tooling economy for short and medium run tooling Benefits Uddeholm Rigor is a tool steel offering good tooling economy for short and medium run tooling when the cost of making the tool is a significant portion of the total cost for producing the required number of parts Uddeholm Rigor is a medium alloyed cold work tool steel with a very good balance between tool performance properties and tool making properties Uddeholm Rigor has a good hardenability and can therefore be used for larger short and medium run tools In East/South East Asia countries served by Assab, Uddeholm Rigor is sold as XW-10. Standard specification W.nr 1.2363 / AISI A2 / AFNOR Z100 CDV5

Uddeholm Stavax ESR is a premium stainless mould steel for small and medium inserts and cores. Uddeholm Stavax ESR combines corrosion and wear resistance with excellent polishability, good machinability and stability in hardening. Mould maintenance requirement is reduced by assuring that core and cavity surfaces retain their original finish over extended operating periods. When compared with non stainless mould steel, Uddeholm Stavax ESR offers lower production costs by maintaining rust free cooling channels, assuring consistent cooling and cycle time. This classic stainless tool steel is the right choice when rust in production is unacceptable and where requirements for good hygiene are high, as within the medical industry, optical industry and for other high quality transparent parts. Uddeholm Stavax ESR is a part of the Uddeholm Stainless Concept. Benefits Low mould maintenance because of corrosion resistance: Surfaces retain their original finish Less production during storing and operation in humid condition Lower production costs: Since water-cooling channels are unaffected by corrosion Heat transfer characteristics, and therefore cooling efficiency, are constant throughout the mould life, ensuring consistent cycle times. Long life mould Standard specification W.nr 1.2083 / AISI 420 / AFNOR Z40 CV 14 (RSL)

Uddeholm Tyrax ESR combines best in class toughness, corrosion and wear resistance. This grade was developed for molding of high performance plastics often filled with glass fiber reinforcements and additives like flame retardants. This matrix- based microstructure is designed to achieve a high-gloss surface by only a few polishing steps, dramatically reducing the tool lead time and enabling production of top quality plastic parts. Uddeholm Tyrax ESR can achieve a high hardness (up to 58 HRC) and is a suitable upgrade from AISI 420 ESR, AISI S7 and AISI 440C. Benefits good dimensional stability at heat treatment and in service even microstructure and small grain size good hardenability Uddeholm Tyrax is also available for Additive Manufacturing, powder for processing Laser Powder Bed Fusion (LPBF) and Laser Metal Deposition (LMD).

Uddeholm Vanadis 4 Extra SuperClean is the most versatile pm tool steel on the market today, combining high wear resistance with very good ductility and resistance to chipping of edges. Excellent machinability in both soft and hard condition ensures advantages in both tool making and tool maintenance. Uddeholm Vanadis 4 Extra SuperClean is also available as powder for processing by Electron Beam Melting technology (EBM). This powder has the same chemical composition as the PM material. Benefits Reliable production with low risk of edge chipping Best combination of high hardness, wear resistance and chipping resistance High compressive strength Best stock standard program of all PM grades Standard specification AISI D2 / AFNOR de type Z136 CDV 5.4

The voestalpine Cooling Liquid Filter CLF-100 is engineered to protect your conformal cooling solutions. The star-shaped stainless-steel sieve offers exceptional filtration performance, effectively preventing particles larger than 100 µm from entering the cooling channel. This filter is a cost-effective investment, reducing the risk of unnecessary downtimes. Experience a reliable operation with our stainless-steel filter, engineered for water-based or oil-based coolants in a temperature range of -10 to +260°C. Achieve maximal coolant flow with an impressive flow rate of up to 80 liters per minute up to a nominal pressure of PN 16. The filter can be flanged to the mold or operated directly with a temperature control unit. The large filter volume and surface ensure extended maintenance intervals. When maintenance is required, the filter cartridge can be removed while the filter housing remains in the system circuit, offering a maintenance-friendly design that reduces downtimes. The filter cartridge itself can be cleaned using compressed air, an ultrasonic bath, or a high-pressure cleaner.

voestalpine Distributors Rings for die-casting applications are produced with premium materials by BÖHLER/Uddeholm. Used mainly in two-plate die casting molds, these finished products include voestalpine heat treatment, final machining, and eifeler PVD coating to deliver high-performance solutions that are ready for foundry use. Our distributor rings offer outstanding high-temperature wear resistance, excellent ductility (gross crack resistance), premium tempering resistance, significant soldering reduction (with eifeler PVD coating), high heat-checking resistance, as well as high thermal conductivity. These superior properties enable reduced maintenance effort and a more constant melt flow, thereby substantially increasing OEE.

Nozzle filters are used to prevent contamination from the plastic melt causing blockages or interruptions to the injection process. These contaminates can cause damage to hot runner systems, resulting in extended downtime and increased maintenance costs. The design of the voestalpine Flow Filter V & X capitalizes on the unique capabilities of additive manufacturing to create a high-density solid mesh filter. Flow Filter X combines filtration and mixing properties, thereby reducing masterbatch consumption. Flow Filter V provides an extremely low pressure drop (up to 65% compared to comb filter). These filters provide improved performance over traditional injection molding nozzle filters and are available in both standard sizes and tailored dimensions. The use of voestalpine Flow Filters increases part quality, reduces scrap rate, significantly reduces shear stresses, and reduces masterbatch consumption. The filters also exhibit high wear- and corrosion resistance as a result of their premium material composition.  

voestalpine Inserts for Bottle Caps have optimized conformal cooling solutions, enabling our customers to run a stable and highly efficient production with a minimized cost per plastic part produced. Our inserts offer higher wear resistance and increased lifetime compared to standard inserts, resulting in lower costs per part produced. Made using our premium steel, our inserts do not contain copper beryllium, which is a potentially toxic element in standard inserts. Many globally active plastic injection molding companies in various industries have confirmed the premium functionality and profitability of our corrosion-resistant inserts for bottle caps.

voestalpine Inserts for Cylindrical Containers are produced using additive manufacturing and have optimized conformal cooling channels that enable our customers to run a stable and highly efficient production. This results in a cost reduction per plastic part produced. Our inserts for cylindrical containers offer an overall cycle time reduction of up to 26% compared to conventionally manufactured inserts. Improved part tolerances are also achieved through homogeneous and conformal cooling design, leading to lower scrap rates and increased productivity.  The inserts are highly polishable, highly ductile (safety against cracks), and have high wear- and corrosion resistance. Many globally active plastic injection molding companies in various industries have confirmed the premium functionality and profitability of our corrosion-resistant inserts for cylindrical containers.

Our Inserts for Food Container lids have optimized conformal cooling solutions, enabling our customers to run a stable and highly efficient production with a minimized cost per plastic part produced. With more homogeneous temperature distribution, our inserts enable improved productivity and can reduce the overall cycle time by up to 15% compared to conventionally manufactured products. Many producers of food container lids have tested our AM solutions and confirmed the increased profitability by using our corrosion resistant inserts for food container lids.

Our AM Inserts for PET-Preform have optimized conformal cooling solutions, enabling our customers to run a stable and highly efficient production with a minimized cost per plastic part produced. Our inserts offer higher wear resistance and lifetime compared to standard inserts, resulting in lower costs per plastic part produced. Made using our premium steel, these inserts do not contain copper beryllium, which is a potentially toxic element in standard inserts. Many PET-preform producers have tested our AM solutions and confirmed the increased profitability by using our corrosion-resistant AM Inserts for PET-Preforms.  

Our AM Inserts for Syringes have optimized conformal cooling solutions, enabling our customers to run a stable and highly efficient production with a minimized cost per plastic part produced. Our inserts offer a refined production process, reducing the overall cycle time by up to 15% compared to sprinkler cooling. Improved part tolerances are also achieved through homogeneous and conformal cooling design, leading to a reduced scrap rate. The polishability requirements (similar to 1.2083) are achieved for 100% of the produced inserts. Many syringe producers have tested our AM solutions and confirmed the increased profitability by using our corrosion-resistant AM Inserts for Syringes.  

Our AM Inserts for Test Tubes have optimized conformal cooling solutions, enabling our customers to run a stable and highly efficient production with a minimized cost per plastic part produced. Our inserts reduce the overall cycle time by up to 30% compared to conventionally manufactured drilled cooling channels. Improved part tolerances are also achieved through homogeneous and conformal cooling design, leading to decreased scrap rates. Many globally active plastic injection molding companies in various industries have confirmed the premium functionality and profitability of our corrosion-resistant AM Inserts for Test Tubes.  

With rising demands for higher part quality, the need for effective process monitoring is increasing. For precise quality monitoring and process control, temperature sensors must be placed at critical points. However, practical constraints like limited accessibility and space due to cooling channels or ejectors often force compromises. This can result in reduced process insights, even with advanced measurement technology. voestalpine Sensorized Inserts overcome these limitations by enabling the seamless integration of internal channels for sensor placement via additive manufacturing. Using our integration know-how, small diameter channels can be realised with precise positioning up to 0.5 mm from the cavity. This approach allows precise process monitoring at critical areas without sacrificing cooling performance. Utilizing the design freedom of additive manufacturing, sensors can be optimally positioned between cooling channels and the cavity wall, eliminating the need for additional drilling efforts. Moreover, conventional thermocouples offer a cost-effective alternative, as they can be installed directly into the mold insert. USE CASES Process monitoring – cavity temperature Process monitoring – blocked cooling channel Switchover for variothermal processes Download datasheet ( under "Downloads" below) for more details!

Proper venting in injection molds is crucial for releasing trapped air and gases. This ensures optimal material flow, uniform cavity filling, and high-quality parts. Inadequate venting can lead to defects such as short shots, burn marks, voids, and weak weld lines, compromising part integrity and appearance. By leveraging the possibilities of additive manufacturing, voestalpine solves these challenges with porous, corrosion-resistant tool steels for injection mold inserts. Microscopic pores allow gases to escape directly through the mold surface without affecting structural strength. The standard component voestalpine Venting Inserts are compact porous plugs, which are easy to integrate into molds, boosting productivity, reducing waste, and ensuring superior part quality. Download datasheet for installation guidelines.

Using additive manufacturing, venting structures with a microscopic porosity can be produced that allow a targeted release of compressed air and ensure that the mold remains air free during injection. These structures help to avoid defects caused by the diesel effect, which is a well-known industrial problem. Our geometry independent venting structures provide application-specific venting performance and allow an easy and customized integration into the mold. Using our corrosion-resistant premium materials by BÖHLER /Uddeholm, the structures ensure high part quality throughout the mold lifetime. The high material and functional quality of our Engineered Products leads to improved overall equipment effectiveness (OEE). This is achieved through a reduction in scrap rates caused by defects such as burn marks and short shots, and a lowering of required injection pressure, which can contribute to energy savings.