Balanced fill
Runner layout designed so every cavity fills and cures the same way, not just the ones nearest the sprue.
Silicone injection (HCR) · Multi-cavity injection
Multi-cavity injection.
More cavities means more parts per cycle and a lower cost per part. It also means a more expensive tool and more places for things to vary. The skill is choosing the right number, not the biggest one.
The detail
Cavity count is a commercial decision
Every extra cavity adds cost to the tool and complexity to the fill. If your demand fills a four-cavity tool comfortably, a sixteen-cavity tool is money spent on capacity that sits idle.
We size the cavity count against the annual quantity you can genuinely commit to, with sensible headroom. Where growth is likely, we design the tool so extra cavities can be added later rather than buying them all on day one.
Where it fits
What we pay attention to
Cavity identification
Each cavity marks its number on the part, so any variation can be traced straight back to its source.
Planned expansion
Tool bases chosen so cavities can be added when volume proves itself.
How we run it
How we bring a multi-cavity tool into production
Volume review
We agree the annual quantity and the growth case, then propose a cavity count and show the maths.
Fill design
Runner and gate layout designed for balance across all cavities.
Cavity-by-cavity first article
First-off parts from every cavity are measured and compared, not just a sample from one.
Ongoing cavity checks
Batch inspection samples rotate across cavities so drift in one position shows up early.
To quote it
Useful for quoting
Committed annual volume
The number you'd put on a forecast to your own board, not the dream figure.
Expected growth
If volume should double in a couple of years, we plan for it now.
Part size and weight
These decide how many cavities physically fit a sensible tool.
Critical features
Features that must match across cavities get extra attention in the fill design.
Questions
What people usually ask.
Is more cavities always cheaper per part?
Up to a point. Beyond it, tool cost, maintenance and cavity-to-cavity variation eat the saving. We'll show you where that point is for your part.
Can you block off a damaged cavity?
Yes. A well-designed tool lets us block a cavity and keep running while it's repaired, with the batch record noting it.
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Back to the overviewDesigned and developed in the UK. UK moulding capability, with some higher-volume production placed with trusted partners where that's the right commercial answer.
Get in touch
Tell us the part, the volume, and the timeline.
Rough annual volume, target unit price, and any deadlines. That's enough to work out whether compression, LSR injection or something else is the right tool.
Real people, a real workshop
You deal with the people who make it.
No call centre and no middlemen. When you contact TCI Products, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
- Real people on the phoneCall the team on 01789 224228, Monday to Friday.
- The same team on every jobDesign, production and aftercare come from the people you see here.
- Part of TCI GroupFive specialist brands, one engineering team. Visit TCI Group.
Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare