Injection Mold Qualification Report Template
Before a new or transferred mold goes into production, a molder needs documented evidence that the tool, press and process make good parts consistently. This template structures that evidence as installation, operational and performance qualification.
Fill in
Injection Mold Qualification Report Template
Injection Mold Qualification Report
Company: Acme Plastics Ltd Mold ID: M-2041 Part: PN-48213 Rev C Cavities: 4 Resin: ABS, general purpose, natural Press: Press 12, 200 metric ton Date: 2026-10-20 Reason: New mold
1. Scope and acceptance criteria
Qualify the mold and process to produce parts meeting drawing requirements over the defined process window. Capability requirement: Cpk of 1.33 or higher on critical dimensions.
2. Installation qualification (IQ)
| Item | Requirement | Result | Pass/Fail |
|---|---|---|---|
| Mold drawing and build records on file | Match current revision | ||
| Mold fits press (tie bars, daylight, locating ring) | Per press datasheet | ||
| Water circuits flow and pressure test | No leaks, flow per spec | ||
| Hot runner controller and zone wiring | All zones reach setpoint | ||
| Ejector, slides and core pulls function | No binding, full stroke | ||
| Calibration of key equipment and gauges | In date | ||
| Resin lot and drying records | Per supplier data sheet |
3. Operational qualification (OQ) - process window
| Parameter | Low setting | Nominal | High setting | Parts acceptable? |
|---|---|---|---|---|
| Melt temperature | ||||
| Mold temperature | ||||
| Injection speed or time | ||||
| Hold pressure and time | ||||
| Cooling time | ||||
| Shot size / cushion |
4. Performance qualification (PQ) - capability run
| Critical characteristic | Specification | Sample size | Mean | Std dev | Cpk |
|---|---|---|---|---|---|
| Characteristic 1 | |||||
| Characteristic 2 | |||||
| Characteristic 3 | |||||
| Weight |
5. Cavity-to-cavity comparison
| Cavity | Part weight | Key dimension | Cosmetic result | Note |
|---|---|---|---|---|
| 1 | ||||
| 2 | ||||
| 3 | ||||
| 4 |
6. Conclusion
Mold and process are qualified for production within the validated process window, subject to the open actions listed.
7. Approvals
A starting-point template, not a regulatory form. Your customer, quality system or industry (for example medical, automotive or aerospace) may require specific forms, sampling plans and validation protocols. Adjust the table rows to your part and process.
Tie qualification records to your ERP part master
Optional: discuss storing approved process settings and qualification evidence with the mold and part records.
Optional. The tool and every export work without this. No spam.
How to use the template
Enter the mold, part, resin and press details, state why you are qualifying, and write the acceptance criteria up front. Print or export the report to Word to add rows for your characteristics and attach measurement data. Complete the IQ table first, then run the process window study for OQ, and finish with a production-length run for PQ. Signatures close the report. Save one per mold and per qualification event.
IQ, OQ and PQ explained
Installation qualification checks that the mold, press, auxiliaries and instruments are set up as intended and in calibration. Operational qualification finds the process window: low, nominal and high settings for the main variables, with parts evaluated at each corner. Performance qualification proves that at nominal settings the process makes capable parts over a run long enough to see normal variation, often judged by Cpk on the critical characteristics. The wording comes from validation practice in regulated industries but works well for any demanding molded part.
Choosing sample sizes and criteria
Use your customer's requirements first. Without one, many shops use capability studies of at least 30 consecutive parts per cavity or a stratified sample across several hours, and a target Cpk of 1.33 for critical dimensions, higher for safety characteristics. Measure cavity-to-cavity variation separately, because a multi-cavity tool is several processes at once. Keep gauge repeatability in mind: if the measurement system is poor, the capability result is unreliable.
- State acceptance criteria before the trial.
- Record the settings used for every sample.
- Include lot numbers of resin and colorant.
- Measure after the part has stabilized.
Common mistakes
Qualifying at a single set of conditions leaves the plant blind to how the process behaves when conditions drift. Measuring parts immediately after molding without allowing time to stabilize can show dimensions that change later, especially for nylon. Skipping a transfer qualification when a mold moves to another press is common and risky, since different presses have different screw, nozzle and control behavior. Also remember to freeze and document the validated settings on the set-up sheet.
Frequently Asked Questions
What is mold qualification in injection molding?
It is documented evidence that a mold and process, run on a defined press and resin, make parts that meet specification consistently. It typically covers installation, process window and a capability run.
When must a mold be re-qualified?
Common triggers are a new mold, a transfer to another press or site, a major repair or modification, and a change in resin grade or supplier. Your customer or quality system may add others.
What Cpk do I need for a molded part?
Many customers ask for 1.33 or higher on critical characteristics, and some ask for 1.67. Always use the customer requirement where one exists.
Is this the same as PPAP?
No. PPAP is a customer approval package, mostly used in automotive. A mold qualification report can be one input to PPAP, supplying process window and capability evidence.
If you want qualification records and approved process settings tied to the mold and part master in your ERP, we can help design that. Ask for a short walk-through.
Related Tools
Injection Mold Maintenance Checklist
A practical preventive maintenance checklist for injection molds, from daily checks at the press to full overhaul and storage.
Industry TemplatesInjection Molding Clamp Tonnage Calculator
Estimate the clamp force a mold needs from projected area, cavity count and average cavity pressure, and see which press size fits.
Industry TemplatesInjection Molding Cycle Time Calculator
Estimate cooling time from wall thickness and temperatures, then total cycle time, parts per hour and output per shift.
Costing & FinanceInjection Molded Plastic Part Cost Calculator
Build up the cost per good molded part from material, machine time, labor, scrap, secondary operations and tool amortization.
More Quality & Inspection tools
See all- Molded Part First Article Inspection Report Template
- Molding Defect and Reject Log Worksheet
- Resin Lot and Dryer Log Worksheet
- Injection Molding Defects, Causes and Fixes Reference
- SAP QM Process Capability Cp Cpk Calculator
- SAP QM Lot Rejection Rate, PPM and Sigma Level Calculator
- SAP QM Gauge R&R Study Calculator
- SAP QM Cp and Cpk Capability Calculator
- Job Shop Material Certification Log Worksheet