Frequently
Asked Questions

Kavia Tooling specialises in the design and manufacture of precision injection mould tools. We offer six core services: injection mould tool design, tool manufacture, repair and modification, CAD/CAM software solutions, plastic component design consultation, and in-house mould trialling and validation. Every service is delivered entirely in-house at our Burnley, Lancashire facility — no subcontracting, complete quality control throughout.

Kavia Tooling is based at 3 Bancroft Road, Burnley, Lancashire, BB10 2RZ. We serve manufacturers across the UK and internationally from our Burnley facility. Tools can be shipped to us, and for local clients we can discuss collection arrangements.

Kavia Tooling has over 20 years of experience in precision injection mould toolmaking. In 2009 we became the first company in the UK to trial and implement Autodesk Inventor Tooling — a distinction that reflects our commitment to progressive technology, which continues today.

Kavia Tooling operates to rigorous quality standards throughout our design and manufacturing processes. Please contact us directly to discuss any specific accreditation or certification requirements your project may have — our team will advise on how we can meet your needs.

Yes. We serve clients both in the UK and internationally. Tools are shipped worldwide from our Burnley facility. Distance is not a barrier to working with us — we manage projects remotely through clear communication, digital design review and agreed shipping arrangements. Call or email us to discuss your situation.

Yes — always. We offer a free initial consultation on any tooling project with no obligation and no hard sell. Whether you have a new component to tool up, an existing tool to transfer or repair, or simply a question about what might be possible — call us on 01282 332110 or email info@kaviatooling.com and one of our senior engineers will get back to you.

We offer six core services, all delivered in-house:

• Injection mould tool design — complete 3D CAD design using Autodesk Inventor Tooling
• Tool manufacture — in-house CNC machining of brand-new tools
• Repair and modification — rapid repair, refurbishment and design-change implementation
• CAD/CAM software solutions — bespoke workflows for the plastics tooling industry
• Plastic component design consultation — DFM review, material selection, tolerance analysis
• In-house mould trialling and validation — every tool tested before delivery

Both. Brand-new tool manufacture is one of our primary services — we design and build tools from scratch entirely in-house. We also offer a comprehensive repair, modification and refurbishment service for existing tools. Many clients use both services, starting with new tool manufacture and returning to us for ongoing maintenance and repair.

Yes — in-house mould trialling and validation is included as standard on every tool we manufacture. We do not deliver tools untrialled. Every tool is tested in our mould shop, first-off samples are produced and inspected, and full production documentation is provided before delivery. This is fundamental to how we work.

Yes. Preventative maintenance programmes can significantly extend tool life and reduce the likelihood of unexpected failures. We assess your tooling and recommend a maintenance schedule tailored to your production volumes, shift patterns and tool types. Prevention is almost always cheaper than emergency repair.

Yes. We produce both prototype and short-run tooling for product development stages, and full production tooling for high-volume manufacture. We will advise on the most appropriate approach for your stage of development and production volume requirements — including when it makes commercial sense to go straight to a production tool.

Yes — hot runner systems are well within our capability. We design and manufacture hot runner tools in-house and can advise on the most appropriate hot runner system for your application, balancing performance requirements with budget and lead time. We work with all major hot runner manufacturers' systems.

We accept STEP (.stp, .step), IGES (.igs, .iges), and native Autodesk Inventor files (.ipt, .iam). 2D drawings in PDF or DXF are also useful for reference and tolerance specification. If you have files in another format, contact us — we will do our best to accommodate. The more information you can provide, the faster and more accurate our design process will be.

We produce the full range of injection mould tool types:

• Single-impression and multi-impression tools
• Hot runner and cold runner systems
• Auto-unscrewing tools
• Moving core tools — hydraulic and mechanical
• Split cavity and 3D cavity tools
• Sprung core tools
• Mechanism tools
• Maintenance tools

We cover everything from budget single-impression tools through to the most complex multi-cavity hot runner systems with integrated mechanisms.

A cold runner tool uses a conventional sprue and runner system — plastic fills the runner channels and must be ejected with each shot, creating material waste and a separate secondary process if runners need removing. A hot runner system keeps the plastic in the runner channels molten between shots, eliminating runner waste, reducing cycle times and improving consistency. Hot runner tools have a higher initial cost but often deliver a faster payback at volume. We can advise which is most appropriate for your application and production volumes.

An auto-unscrewing tool is used to produce components with internal or external threads. Rather than requiring manual unscrewing of the component from the thread-forming core — which is slow and inconsistent — the tool incorporates a mechanism (typically rack and pinion or gear-driven) that automatically rotates the threaded core during ejection, releasing the component cleanly each cycle. Kavia designs and builds auto-unscrewing tools as a standard part of our capability.

Yes — multi-cavity tooling is a core part of our capability. The maximum number of cavities depends on the component size, complexity and the press capacity of your moulding machines. We will discuss your production volumes and machine specifications and recommend the most appropriate cavity count to give the best balance of tool cost, cycle time and output. Contact us to discuss your specific requirements.

Yes. We design tools for the full range of thermoplastic materials — from commodity grades like PP, PE, ABS and PS through to engineering plastics including PA, POM, PBT, PC and PEEK, and glass-filled, mineral-filled and flame-retardant compounds. Material selection significantly influences tool design decisions — steel grade, cooling design, gate type and surface finish requirements all vary by material. Our plastic component consultation service can help if you are still selecting a material.

We use Autodesk Inventor Tooling as our primary CAD/CAM platform. Kavia Tooling was the first company in the UK to trial and implement Autodesk Inventor Tooling in 2009 — we have 15+ years of specialist expertise with the platform, which translates directly into faster, more accurate and more efficient tool designs for our clients.

In 2009, Kavia Tooling's management recognised that Autodesk Inventor Tooling represented a step change in what was possible in injection mould tool design — and took the decision to adopt and implement it ahead of the rest of the UK industry. That pioneering adoption required significant investment in training and process development, but it established a capability advantage that we continue to build on today.

Our fully parametric 3D CAD approach delivers: greater precision and repeatability; the ability to analyse designs before machining begins; design changes that propagate automatically through all dependent geometry; direct output to CNC machining programmes with no manual re-entry; 3D visualisation for client review and approval; and complete digital documentation and traceability throughout the project.

Always. Once the 3D tool design is complete, we share it with you for review and approval before any manufacturing begins. We walk through the design, confirm all requirements are met, and make any agreed modifications. Nothing goes into our CNC machines until you are satisfied with the design.

Our CAD/CAM workflow is fully integrated — CNC machining programmes are generated directly from the 3D CAD model. This eliminates manual re-entry of dimensions and the transcription errors that come with it, ensuring absolute accuracy between the design intent and the machined tool. The same digital model also drives the inspection plans and tooling documentation.

Yes. We use your component CAD data as the starting point for tool design — deriving core and cavity geometry directly from the component model, adding shrinkage allowances, designing the mould base, runner system, ejection and cooling around it. We accept STEP, IGES and native Inventor files. If your data is in another format, contact us to discuss.

Turnaround time depends on the nature and extent of the damage. For emergency situations where production has stopped, we prioritise your tool and work as quickly as possible. Call us immediately on 01282 332110 and we will assess your situation, give you an honest timeline and advise on what can be achieved and when. We never over-promise on speed — but we work as fast as quality allows.

• Emergency rapid repair — production-stopped situations prioritised
• Worn cavity and core replacement
• Gate and runner system modification
• Ejector system repair and replacement
• Hot runner system servicing and heater replacement
• Tool modification for design changes
• Full refurbishment and life extension
• Preventative maintenance

Always. We carry out a thorough inspection of the tool first, then provide a detailed, transparent quote before any repair or modification work begins. There are no hidden costs and no surprises. For emergency repairs, we can provide an initial assessment quickly so you can make an informed decision without unnecessary delay.

Yes — tool modification is a core part of our service. Whether you need a minor geometry change, a gate relocation, a significant design change or integration of new features into an existing tool, our team can assess the feasibility and carry out the modification in-house. Modification is almost always faster and more cost-effective than commissioning a new tool for incremental design changes.

Yes — every repair and modification is carried out entirely in-house at our Burnley, Lancashire facility by our own skilled toolmakers. We never subcontract repair work. This gives us complete control over quality, turnaround time and communication throughout the process.

It depends on the tool's condition, age and the nature of the component design. In many cases, a refurbishment is significantly more cost-effective than a new tool and can extend productive life by many years. In others — particularly where the component design has changed significantly or the tool is beyond economic repair — a new tool makes more commercial sense. We will give you an honest assessment of both options and their relative costs, without pushing you towards either.

A plastic component design consultation is an expert review of your plastic part design before tooling begins. It covers design-for-manufacture (DFM) principles — wall thickness, draft angles, undercuts, gate location, parting line definition, material selection, tolerance analysis, sink and warpage risk — to identify and resolve potential issues before they become expensive tooling problems.

Yes — Kavia Tooling's initial plastic component design consultation is free with no obligation. Send us your component drawings and our engineering team will review them and provide initial feedback. Contact us on 01282 332110 or email info@kaviatooling.com to arrange yours.

Changes made at the design stage cost a fraction of what the same changes cost after tooling has started or been completed. A DFM review identifies geometry that will cause moulding defects, tooling complications or excessive cycle times — and resolves them when resolution is still cheap and quick. A change that takes minutes in CAD can cost thousands of pounds once steel has been cut.

Yes — material selection is a core part of our consultation service. We advise on the most appropriate polymer material and grade for your application, considering mechanical performance, chemical resistance, processing characteristics, appearance requirements, regulatory requirements (FDA, RoHS, REACH etc.) and cost. Getting this right early avoids costly material changes later in the programme.

Yes. We regularly work with manufacturers experiencing persistent quality problems — sink marks, warpage, short shots, weld line failures, dimensional instability, or high scrap rates. We can review your component design, tooling and process parameters and recommend modifications to the component design or tooling that will resolve the issues. Contact us to discuss your situation.

Our process follows five stages:

• Brief and consultation — we thoroughly understand your requirements, volumes, material and budget
• Design and CAD — our engineers develop a precise 3D tool design using Autodesk Inventor Tooling and share it with you for review and approval
• Manufacture — the tool is manufactured in-house using our advanced CNC machinery
• Trial and validate — every tool undergoes rigorous in-house mould trialling and validation
• Deliver and support — the production-ready tool is delivered on time, with full documentation and ongoing support

Lead times depend on the complexity of the tool. A straightforward single-impression tool can be designed, manufactured and trialled in as little as 4–6 weeks. Complex multi-cavity tools with hot runners and mechanisms will take longer. We always provide a realistic lead time during our initial consultation — and we commit to deadlines that we can achieve, not aspirational ones that we can't.

Yes — open communication throughout the project is fundamental to how we work. We keep you informed at every key stage: design completion and review, manufacture milestones, trialling results and delivery scheduling. You will never be chasing us for an update. If something changes, we tell you immediately and discuss the implications.

We provide comprehensive production documentation with every tool, including: first-off sample inspection reports, process parameters (temperatures, pressures, cycle times), material specification confirmation, dimensional inspection data, and any First Article Inspection (FAI) reporting agreed during the project. This documentation gives your production team everything they need to run the tool from day one.

We remain available for technical support after delivery — answering questions about the tool and its operation, advising on process optimisation and responding to any issues that arise. For ongoing support, our repair, modification and preventative maintenance services ensure your tool continues to perform at its best throughout its productive life.

We serve automotive, aerospace, medical, electronics, consumer goods, industrial manufacturing, defence and UK reshoring sectors. Our tools are tailored to the specific requirements of each industry — regulatory, technical and production volume demands all vary significantly between sectors, and we understand these differences.

Yes. We design and manufacture injection mould tools for automotive manufacturers across EV, hybrid and traditional combustion vehicle platforms — covering interior trim, under-bonnet components, exterior body parts, lighting components and structural parts. Our tooling meets OEM supply chain quality standards.

Yes. We produce precision tooling for medical device manufacturers — covering surgical instruments, implants, diagnostic equipment and medical consumables. We produce tools with full documentation, traceability and in-house validation, and understand the regulatory environment that medical manufacturers operate in. Contact us to discuss your specific requirements.

Yes — UK reshoring is something we actively support. We manage the full process: technical assessment of existing tools, transfer logistics advice, refurbishment or modification where required, in-house validation and production support. Many manufacturers find total cost of ownership is significantly lower with a UK partner when communication, shipping, repair lead times and quality risk are properly factored in.

Probably yes. Our precision injection mould tooling capability extends across a wide range of manufacturing sectors. If you are a manufacturer who uses injection moulded plastic components, we can almost certainly add value to your tooling. Call us on 01282 332110 for a straight conversation about whether and how we can help.

The easiest way is to call us on 01282 332110 or email info@kaviatooling.com with your component CAD data (STEP or IGES) and a brief description of your requirements — volumes, material, any specific tolerances or cosmetic requirements, and your target delivery date. We will review your data and get back to you with expert advice and a competitive quote promptly. The initial consultation is always free.

The main factors that influence tool cost are:

• Component complexity and size
• Number of cavities
• Tool type — single impression, multi-cavity, hot runner, moving cores etc.
• Material — tool steel grade and surface treatment required
• Production volumes and target tool life
• Required tolerances and surface finish
• Lead time requirements

We will discuss all of these during our initial consultation and provide a detailed, transparent quote.

No. Our quotes are detailed and transparent — we itemise the scope of work and what is included. Mould trialling and validation is included as standard on all new tools. The only time costs change is if the scope of the project changes — in which case we discuss it with you before proceeding, never after.

Yes — we offer competitive pricing without compromising on quality. We are a UK manufacturer and our prices reflect that, but when you factor in the total cost of ownership — fast repair access, no language or timezone barriers, short shipping times, in-house validation included, and the cost avoidance of quality problems — many clients find UK tooling from Kavia is highly competitive even against overseas alternatives. We are happy to discuss this openly.