Plastic pallet injection molds · turnkey programs

Load, entry and racking designed into a production tool

Injection-mold programs for 800×600 to 1500×1500 mm pallets: nine-foot nestable, 3-runner, cruciform, double-face and steel-reinforced decks. DFM, multi-drop hot runners, regrind filtration, T1 tryout and load checks — tooled to dynamic / static / rack ratings.
√ 200+
√ Chair mould projects
√ 1,000,000
√ Shot life potential
√ ±0.05mm
√ Critical tolerance
√ 30+
√ Export markets
Application Coverage
Five base styles, four tooling strategies
A pallet tool is not a flat plate. The work is leg draft, anti-slip texture, steel-tube overmold, four-way fork clearance and long-flow filling with regrind.
Three-runner / three-beam rack pallet molds
Three-runner / three-beam rack pallet molds produce standard plastic pallets in sizes such as 1200×1000, 1200×800, and 1300×1100. With three continuous beams at the bottom, they suit rack storage and four-way fork entry, widely used in warehousing, food and beverage, chemicals, pharmaceuticals, and automotive parts. Pallets are typically made of HDPE for impact resistance, low-temperature performance, and reusable circulation. Mold design focuses on beam stiffness, fork opening dimensions, anti-slip teeth, and optional built-in steel tube channels. 718H or 1.2738 steel is recommended, with a 16+ valve gate hot runner system for balanced filling over large projected areas. Overall advantages include high load capacity, rack suitability, and optional steel tube reinforcement.
Nine-leg stackable pallet molds
Nine-leg stackable pallet molds are used to produce lightweight plastic pallets with nine conical legs at the bottom, allowing empty pallets to nest and stack, significantly saving storage and return transport space. They are widely used in light-duty turnover, warehousing, and empty pallet return. Mold design focuses on controlling leg taper and wall thickness uniformity to avoid stress whitening, sink marks at the leg base, and unstable stacking — ensuring smooth nesting, reliable load capacity, and convenient reusable circulation. Overall advantages include lightweight design, nestability, and space saving — ideal for light-duty logistics and turnover.
Picture-frame / rackable pallet molds
Picture-frame / rackable pallet molds are used to produce plastic pallets with a grid-shaped bottom structure, commonly used in automated high-bay warehouses and drive-in racking. They are widely applied in warehousing, food and beverage, chemicals, and pharmaceuticals. Mold design focuses on balanced mold flow, especially weld line control at the cross intersections to avoid weak strength and appearance defects. The cooling system must also minimize warpage across large flat areas to ensure flatness and dimensional stability. Overall advantages include even load distribution, rack suitability, and structural stability — meeting the requirements of high-density storage and automated high-bay warehouses.
Flat closed-deck pallet molds
Flat closed-deck pallet molds are used to produce plastic pallets with a fully closed top surface, featuring easy cleaning, no material accumulation, and high hygiene standards. They are widely used in food, pharmaceutical, fresh produce, and daily chemical industries with strict hygiene requirements. Mold design focuses on top surface polishing, eliminating dead corners where material can accumulate, and sealing edge structure — ensuring a smooth, seamless, and easy-to-clean surface that meets hygiene-grade standards. Overall advantages include easy cleaning and reliable hygiene, ideal for high-standard food and pharmaceutical applications.
Workflow
Custom Pallet Mold Development Process
From initial 3D conceptualization to final trial shot testing in our high-tonnage injection machines, our streamlined 6-stage process ensures total transparency.
Discuss the product dimensions, structure, appearance, material, mold steel requirements, injection machine tonnage, and other key information needed for product design.
Communication of requirements
Discuss the product dimensions, structure, appearance, material, mold steel requirements, injection machine tonnage, and other key information needed for product design.
Step 1
The documents to be confirmed include: product 3D drawings, mold drawings, and any related drawings required for mold flow analysis, if applicable.
Technical Drawing Approval
The documents to be confirmed include: product 3D drawings, mold drawings, and any related drawings required for mold flow analysis, if applicable.
Step 2
Prepare the required steel according to customization needs, and arrange mold processing such as CNC machining, EDM, deep-hole cooling, polishing and texturing, as well as steel heat treatment.
Custom Materials & Mold Processing
Prepare the required steel according to customization needs, and arrange mold processing such as CNC machining, EDM, deep-hole cooling, polishing and texturing, as well as steel heat treatment.
Step 3
Conduct trial molding and send samples to the customer for confirmation, and keep improving the mold until the customer approves it as qualified.
Trial Sample Approval
Conduct trial molding and send samples to the customer for confirmation, and keep improving the mold until the customer approves it as qualified.
Step 4
Prepare the mold 2D/3D drawings, inspection reports, etc., and customize wooden crates as required, arrange booking, and confirm the shipping schedule.
Shipment and Delivery
Prepare the mold 2D/3D drawings, inspection reports, etc., and customize wooden crates as required, arrange booking, and confirm the shipping schedule.
Step 5
Provide services such as rapid response, technical support, repair and maintenance, and spare parts supply for customers' mold usage.
After-sales Follow-up Service
Provide services such as rapid response, technical support, repair and maintenance, and spare parts supply for customers' mold usage.
Step 6
Engineering solutions
Six jobs on large, long-flow, recycled parts
Pallets have huge projected area, dense rib grids and long flow paths. Success is drop count, filtration, cooling zones and warp control — not just more clamp force.
√ Multi-drop hot-runner fill
A 1210 pallet typically uses 12–24 valve gates. Shorter flow, lower pressure, welds kept off the main beams. Sequence outer grids first, then the centre.

√ Regrind filtration
A filter ahead of the manifold handles flake and regrind, cuts nozzle blockages and black specks so recycled lines can run continuously.

√ Zoned / conformal cooling
Separate loops for deck, runners and feet. BeCu near thick ribs and tube pockets. Target 80–140 s while holding diagonal warp.
√ Steel-tube overmold
Rack-rated decks often embed galvanized square tube. Locating pins, anti-rotation seats and wrap windows keep tubes from shifting or showing.
√ Grip texture and ejection
Top grip and bottom strips need a texture code and extra draft. Stripper + pins + air assist protect the grid from tear.

√ Steel graded to life
P20 for proto and mid volume; 718H / 2738 for large plates that must stay flat; local H13 where recycled resin is abrasive. 300k–1M shots.
Spec Sheet
Configurable Mould Parameters
Typical ranges only. Final build follows part size, resin grade and target output. Part size determines mold structure and machine tonnage; resin grade determines steel and runner system; target output determines tool life and steel grade. Cooling, surface finish, lead time and budget should also be confirmed together.
ItemOptions / ValuesNotes
Cavity / Core SteelP20, 718H, 2738, NAK80, H13, S136Selected by tool life and polish requirements
Cavity / Core HardnessPre-hardened steel HRC 30–35; Heat-treated steel HRC 48–52Directly affects wear resistance and mold life
Mold BaseLKM / HASCO / DME / MISUMILKM S50C or P20 are common choices
Runner SystemHot runner (pin-point gate) / Cold runnerHot runner is common for chairs to reduce cold scrap and improve efficiency
Number of CavitiesSingle cavity (large chairs) / Multi-cavity (stools)Large chairs are usually 1-cavity; small parts can be multi-cavity
ResinsPP, HDPE, ABS, PC, regrindPP is commonly used for chairs; UV-stable PP required outdoors; glass-filled resins need wear-resistant steel
Tool Life300,000 – 1,000,000 shotsP20 approx. 200,000–300,000; 2738/heat-treated steel can reach 600,000–1,000,000
Cycle Time35 – 70 s1.3–2.5 kg chairs: 45–66 s on standard machines; 35–50 s on high-efficiency machines
Injection Machine Tonnage650T – 1650TStandard chairs approx. 850T; PC chairs / gas-assist chairs require 1350T+
Clamp Force CheckProjected area × cavity pressure (350–500 kg/cm²) × 1.17 safety factorMust exceed the parting force; insufficient clamp force causes flash
Surface FinishMirror / grain / rattan EDMParting line should be smooth to the touch
Corrosion ConsiderationPVC/POM/PBT and other corrosive resins require S136, 2316Halogen-containing or acidic plastics require stainless steel molds
CAD / CAEUG, SolidWorks, Pro/E, AutoCAD, MoldflowFill and cooling studies completed before steel is cut
Tools, lines and finished pallets
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Fill out a Request a Quote form
Prepare your project details and glass manufacturing specifications, and we will provide you with a quote within 24–48 hours.
Once the sample or drawing is received, we will provide a solution within 2 working days to ensure you get the best product for your project.
Send Sample/Picture/3D
Once the sample or drawing is received, we will provide a solution within 2 working days to ensure you get the best product for your project.
Once the drawing is confirmed, you can book online, and we will arrange production as soon as possible.
Order Online
Once the drawing is confirmed, you can book online, and we will arrange production as soon as possible.
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