More than 95% of automotive parts rely on it—how do these “small molds” drive a “big industry”?

Reported by Wang Weiqiu of Dongfang.cn on April 28: Annual sales reached 31 million units, up 3% year-over-year; the penetration rate of new energy vehicles surpassed 50%; and exports topped the global rankings at 6.407 million units… In 2024, China’s automotive industry achieved milestone development, delivering an outstanding “report card.” In automobile manufacturing, more than 95% of components rely on molds for forming—from body panels to precision electronic components—with molds playing a role throughout the entire product lifecycle. Amid the wave of electrification and intelligentization, automotive molds—often referred to as the “mother of industry”—are moving from behind the scenes to the forefront. From the precise shaping of body panels to the integrated molding of battery components, and from the application of new materials for weight reduction to multi-process composite mold technology, molds have become the core pillar supporting automakers in reducing costs, improving quality, and responding rapidly to market demands.

Recently, as a key concurrent event of the 2025 Shanghai Auto Show, the “2025 Shanghai International Automotive Forming and Manufacturing Industry Dialogue,” jointly organized by the China Die & Mold Industry Association and the China Association of Automobile Manufacturers, was held. Representatives from leading companies in the automotive manufacturing, parts, and mold industries gathered to engage in in-depth discussions on the core theme of “Innovative Technologies Empowering Industrial Chain Collaboration.” They explored technological breakthroughs, supply chain transformations, and global competition strategies in the field of automotive forming and manufacturing, infusing “mold wisdom” into industrial upgrading for the era of new energy vehicles. Molds are not only “industrial amplifiers” but also vehicles for technological innovation. Qin Ke, Executive Vice President of the China Die & Mold Industry Association, explained that hot-forming dies for high-strength steel help reduce vehicle body weight by 20 percent, in-mold electronics (IME) technology enables the integration of automotive interior functions, and lightweight material forming technology enhances the driving range of new energy vehicles. “Every breakthrough in die and mold technology is reshaping the competitiveness of the automotive industry.”

At the scene, reporters saw a physical product manufactured using “IME (In-Mold Electronics) technology”—an automotive interior door panel control assembly capable of controlling various functions such as door locks, seats, and rearview mirror adjustments. At first glance, it appears to be an “unremarkable” plastic panel, but when turned over, it reveals “hidden ingenuity.” The back of the part is neatly covered with various circuits, touch switches, and LED lights. Thanks to mold innovation, this small panel can perform functions that would traditionally require at least three separate components, while also enhancing its aesthetic appeal. Ye Shengji, Chief Engineer of the China Association of Automobile Manufacturers, pointed out that the industry currently faces four major trends: policy-driven low-carbon transformation; electrification and intelligentization driven by technological iteration; deepening supply chain collaboration; and enhanced international cooperation. “Consumer demand for model diversity is forcing automakers to accelerate flexible production, and the customization and high precision of molds are key to achieving this goal,” Ye Shengji emphasized. He noted that the mold industry must respond to the new challenges posed by new energy vehicles through innovation; for example, high-strength aluminum alloy die-casting for battery casings and integrated stamping of body structural components all place higher demands on mold design and manufacturing. In fact, many people have noticed that cars have become increasingly affordable in recent years. However, this is by no means the result of “cutting corners”; rather, it stems from an ever-increasing pursuit of excellence in the manufacturing process, as well as the mold industry’s continuous acceleration of technological innovation to reduce production costs. For example, for lightweight materials such as aluminum alloy and carbon fiber, the industry has developed wear-resistant, high-precision mold steels and surface treatment technologies; promoted efficient production solutions like multi-cavity molds and progressive dies to achieve “multiple parts from a single mold” and reduce production costs; and utilized digital twins and AI algorithms to optimize mold design, shortening the trial mold cycle by more than 30% to meet automakers’ needs for rapid model changes. So, to what extent can the production of a single automobile be improved through technological upgrades? Dong Zhichao, Assistant General Manager of FAW Mold Manufacturing Co., Ltd., explained that in terms of white body technology upgrades, a single front fender can be reduced from nine parts to just one through technological iteration, while also achieving weight reduction. Looking at the white body as a whole, the number of parts has been reduced to 334, significantly lowering manufacturing costs. At the same time, the practical application of “multi-part per mold” techniques—such as producing four door outer panels or three trunk panels from a single mold—has led to significant optimizations in total mold investment and overall mold weight. It is reported that the 24th China International Mold Technology and Equipment Exhibition (DMC2025) will open on June 4 at the Shanghai New International Expo Center. Under the theme “High Technology, High Efficiency, High-Quality Intelligent Manufacturing,” the exhibition features a dedicated automotive mold zone, bringing together more than 150 leading enterprises—including FAW Mold, Tianjin Automotive Mold, Yinbaoshanxin, and Haitai Ke—to showcase cutting-edge achievements such as lightweight forming technologies, intelligent mold production lines, and mold full-lifecycle management systems.

Currently, China’s automotive mold technology has joined the world’s top tier, achieving import substitution in areas such as high-precision stamping molds and complex cavity molds, and exporting to markets in Europe, the United States, and Southeast Asia. As DMC2025 approaches, the industry will usher in a new round of technical exchanges and commercial cooperation, further solidifying the position of “Chinese molds” in the global automotive supply chain. Industry experts note that molds are the “hidden champions” of the automotive industry, and their technical level determines the upper limit of automotive manufacturing. At this critical juncture, as the new energy vehicle sector shifts from “scale competition” to “value competition,” only through deep collaboration across the supply chain and continuous technological innovation can China’s “smart manufacturing” gain greater influence on the global stage. Data shows that the scale of China’s automotive mold industry has already exceeded 200 billion yuan. As the penetration rate of new energy vehicles rises, the market size is projected to surpass 250 billion yuan by 2025, with demand for integrated die-casting molds and battery box molds growing at a rate exceeding 20%. This industrial transformation, sparked by “small molds,” will continue to reshape the future landscape of global automotive manufacturing.