Mold lifting equipment for injection molds and dies

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FullSharp · since 1991

Quick answer: Injection molds and stamping dies of 20–500 kg should be lifted with dedicated equipment instead of by hand or by waiting for the shop crane. Manipulators (20–250 kg) reach horizontally into the machine and can rotate or tilt the mold; pneumatic jib cranes (up to about 200 kg) suit single machines; 200 kg aluminum or 500 kg steel rail systems cover the mold rack and several machines; servo hoists (20–750 kg) handle heavier molds that need precise positioning. The gripping tool (eyebolt, vacuum or side clamp) is designed for each mold.

When the whole team waits for the crane to change a mold

"Every mold change, the whole team stands around waiting for the crane, and the mold is only a hundred kilos." We hear this so often on surveys at injection molding and stamping shops that it no longer surprises us. A small injection mold already weighs 20–50 kg, and mid-size stamping dies and molds are usually 100 to 500 kg. Too heavy to carry by hand, yet too light, and changed too often, to call the big shop crane over every time.

Lifting the mold is the easy part. The hard part is the last few centimeters, setting it down on the machine table so it meets the locating pins and drops between the guide posts. A mold hanging on a chain or wire rope keeps swinging, someone has to steady it by hand, and one light knock can chip an edge or pinch a finger. So when you look at mold lifting equipment, the question that matters is whether the operator can place the mold gently and exactly where it belongs. Every option in this article can handle the weight.

Where you can grip the mold decides most of the setup

The first thing we do on site is look at where the mold can be held. Most molds already have threaded holes for eyebolts. That is cheap and simple, and works with a jib crane, a rail-mounted hoist or a lifter with a hook. A mold hanging from one point will rotate, though, so the operator needs a guide handle to keep it square while setting it into the machine.

If the top face is flat, smooth and large enough, a vacuum lifting pad works well. No eyebolts to fit, just place the suction cups and lift, and release is quick, which suits shops that change small molds several times per shift. The face does need to be free of oil.

When the mold has to go horizontally deep into the machine, or be rotated or tilted from flat to upright, we build a side clamp driven by a motor or cylinder. Once clamped, the mold moves with the arm and does not sway. FullSharp designs this gripper for each mold, so send us photos or drawings as early as you can.

Comparing common mold lifting equipment

These are the five types of equipment we install most often in mold change areas. Capacities are typical ranges; the actual configuration depends on the mold and the building.

Equipment	Typical capacity	Best for	Notes
Lift-assist manipulator	20–250 kg	Reaching horizontally deep into the machine, rotating or tilting the mold	Rigid arm, no swinging; limited working radius
Pneumatic jib crane	Up to about 200 kg	One machine or a small cell, lifting molds onto the table	Mold hangs under the hook, use a guide handle when aligning
Overhead rail system with hoist	Aluminum rail 200 kg, steel rail 500 kg	Covering a rectangular area: mold rack and several machines	Needs a strong ceiling or a freestanding frame
Servo balancing hoist	20–750 kg	Heavier molds that need millimeter-level positioning	The mold feels weightless in hand; higher cost than a standard hoist
Electric lifter with mold hook	Depends on configuration	Moving molds between storage and machines without fixed structures	Needs wide aisles and a flat floor

What we have built, and why each shop chose differently

In CNC shops, some customers use a pneumatic jib crane right beside the machine, some a 120 kg ceiling-mounted manipulator that reaches into each machine, and one uses an articulating jib crane with a vacuum pad to pick molds and set them on the table. Where molds are changed all day long, we usually propose an electro-pneumatic manipulator with a motorized mold clamp, or a manipulator with a multi-cup vacuum tool.

Along a long row of machines, a 500 kg steel rail line with a servo hoist runs the length of the row and handles both workpieces and molds. One shop had its machines on the second floor, inside a cold room where the ceiling could not be drilled, so we put up a freestanding 200 kg aluminum rail frame on the floor. And when molds travel between several areas, from the mold store to machines far apart, an electric lifter with an articulating mold hook is more flexible than any fixed structure. Photos of these projects are below the article.

What to prepare before you call us for a survey

Start with the weight of your heaviest mold, plus the gripper, which is usually a few dozen kilograms. The equipment should be rated comfortably above that total, not right at it. Next, the mold size and where it can be held: eyebolt holes, a flat face for vacuum, or only the two sides for clamping.

Then the path the mold takes. How far is the rack from the machine, and does the mold have to slide deep under the machine guard? If it has to go in horizontally, the answer is almost always a manipulator, because a rigid arm can do what a hook cannot. Tell us too if the mold must turn 90 degrees or be stood upright, since the tool will need a rotate or tilt mechanism.

Finally the building: ceiling height, whether columns can take extra load, whether there is compressed air or only power, and whether it is a clean room or cold room. With this information we can usually settle the solution in a single site visit.

A few safety points we always repeat

Eyebolts must match the thread size and be screwed in fully. Mold threads wear after many changes, so check them before each lift. Pneumatic units should have a holding valve and electric units a brake, so that if air or power is lost halfway the mold simply stays where it is.

With vacuum pads, a vacuum gauge and a low-pressure alarm are a must, and the mold face must be wiped clean of oil before lifting. One habit we remind every shop about: never put a hand under a suspended mold. Lower it onto solid supports first, then adjust. Mark the rated capacity clearly on the equipment so new operators see it too.

Real projects installed by FullSharp

Ceiling-Mounted 120 kg Manipulator for Loading Molds into CNC Machines

Pneumatic Manipulator with Mold Vacuum Lifter for Factories

Electric-Pneumatic Manipulator with Motorized Mold Gripper

Lifts All Articulating Jib Crane with Vacuum Lifter for CNC Mold Loading

Pneumatic Jib Crane for Mold and Workpiece Handling at CNC Machines

200kg Aluminum Rail Freestanding Frame for Mold Lifting in a Cold Room, 2nd Floor

FULLSHARP Mold-Hooking Lifter with Flexible Articulating Arm

Equipment in operation (videos)

Manipulator vacuum lifting a heavy metal block

Articulating jib crane moving freely around machines

Manipulator assisting mechanical part assembly

Frequently asked questions

What equipment should I use to lift a 100 kg injection mold?

If you only lift the mold onto the machine table, a pneumatic jib crane or a rail-mounted hoist is enough. If the mold must go horizontally deep into the machine or be rotated, use a manipulator with a clamping or vacuum tool.

Can a vacuum lifter be used to lift molds?

Yes, when the top of the mold is flat, smooth, oil-free and large enough for the suction cups. The unit must have a vacuum gauge and a low-pressure alarm. Molds without a flat face use eyebolts or side clamps.

What is the best option for 300–500 kg molds?

Usually a 500 kg steel rail with a hoist, or a servo balancing hoist when precise positioning is needed. Standard manipulators suit molds up to about 250 kg.

Can a mold lifting rail be installed if the ceiling cannot be drilled?

Yes. FullSharp uses a freestanding frame on the floor to carry the rail, as in our 200 kg aluminum rail frame for mold lifting in a second-floor cold room.

What happens if air or power fails while lifting a mold?

Pneumatic manipulators have a holding valve and electric units have a brake, so the mold stays in position until air or power returns and the operator lowers it safely.

Send FullSharp a photo or drawing of the mold, the weight of the heaviest mold, the machine type (injection, stamping, CNC) and the layout from mold rack to machine for a free survey and equipment and tooling proposal.

Request a site survey View manipulator projects

Lifting injection molds and stamping dies: choosing the equipment