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  • Injection Moulded Microfluidic Device for Bio-tech Company Droplet Genomics

    Droplet Genomics is a bio-tech company disrupting new ground in high performance analysis technologies. This company enables scientists get into and explore the vast field of biology world. Droplet Genomics produces tools for the scientists that are easy and simple to use for their explorations and precise findings. The core focus of this company is a droplet microfluidics technology which provides unmatched capabilities for researching the cosmos of biology. This technology empowers scientists to investigate biological samples at the resolutions of a single cell. In combination of life sciences, machine learning and engineering this company provides a whole platform for a high-throughput exploration. What are the microfluidic chips? Microfluidic chips are the components that are used in high-throughput biological research. They are the core in fluidic droplets handling operations: generating, splitting, merging, mixing, storing, injecting. Such platform contains micro-channels, obstacles and reservoirs to achieve these operations. It requires a great deal of knowledge to design such structures and channels to achieve the desired goal of the chip. However, manufacturing of such systems requires no less of knowledge too. High volume chips’ production When microfluidic channels are tested and confirmed for the desired research objective, higher volume of the chips may be demanded and this is where Micromolds℠ company with micro injection moulding could step in and cooperate with Droplet Genomics. Not only does injection moulding come handy because of its high productivity but also because it enables the possibility to make non-micro structures – like the reservoirs, wells, inlet and outlet gates together with micro geometries in one single moldable piece. However, this comes at a certain cost which is challenging for any injection molding professional. Tooling challenges When things get really small, regular machining might not be an option even though theoretical machine and tool precision would let do so. For such micro tools we had to use tool inserts that are located inside the mold base. Since the high plastic injection pressures forces are exerted inside the mold cavity and core, we had to experiment a lot with different machining options of those inserts – from laser ablation to multiphoton polymerization. Manufacturing the insert is just one side of a coin, the most challenging task was to locate the insert inside the mold base so that alignment of the core and cavity would be perfect and the clamping forces would not brake the inserts. Injection Challenges Extremely flat surface of the chip was needed to make micro geometries possible. This meant that any sink marks caused by the uneven wall thickness had to be solved. However, we could not make walls thinner than the smallest ejectors we had since this would have caused us demolding problems. In fact, it did. At the first trials the ejectors were too weak and started to bend. As a way out we had to play with injection parameters to reduce the sink marks to the minimum so the wall thickness could remain unchanged and thus thicker ejectors could be used. The results We are happy that we were given an opportunity to grow together with our client in solving really challenging tasks. Such projects force us to enter to the whole new market of microfluidic chips molding. There is no doubt our companies will continue on cooperating in the future to enable high-efficiency biological exploration through droplet microfluidic technology.

  • How Micromolds℠ help “Teltonika IoT Group” save time and costs when launching new products

    1300 employees 18 countries 27 offices This is how big Teltonika IoT Group is. The IoT group subsumes 5 subsidiary companies working in: Telematics (tracking hardware), Networks (professional networking equipment), Mobility (personal tracking, asset tracking and electric mobility) telemedicine (pulmonary ventilator and other healthcare devices) and EMS (manufacturing). The product Teltonika Telemedic almost two years ago initiated an innovative smart watch development project in the telemedicine industry. Teltonika Telemedic developed a device that can detect continuous ECG levels and atrial fibrillation. A smartwatch now undergoes the final technical checks and certification procedures. Clinical trials were carried out which delivered extraordinary results demonstrating high accuracy of ECG recording – 99,2% compared with in-hospital ECG holters. It indicates high precision to distinguish atrial fibrillation from other arrhythmias reaching 99,1 %, tested with more than 30 % of patients with frequent arrhythmias symptoms. The use of PPG in continuous monitoring of heart activity will allow detecting irregular heart rate in a timely manner even if there are no symptoms felt by the user. Thus, the smartwatch would detect asymptotic atrial fibrillation and prevent heart diseases if patients are diagnosed as early as possible. The design To fit all of these technological features into a usual every-day smartwatch is quite a challenge both for designers and manufacturers. “The conception of design is not a job that takes one day or a month to complete. It is way more than you can think of. It took us nearly half a year to develop the design that it is right now. We put a lot of thought into producing a unique design which would be intuitive to use.” – says Eimantas Ramunis, Product Owner at Teltonika Telemedic. Many smartwatches in medical and consumer markets were compared and analysed, the flaws were determined to outperform competitors and stand out of the crowd. Teltonika design team came up with nearly five different designs. Thus, not surprisingly, it was even more difficult for the whole team to choose the best one not only from the design point of view but also from manufacturing. The case A good designer knows that what looks and feels good does not always work out with technological aspects and might cause problems with manufacturability. To speak numbers – the watch will have six sensors contacting with human. From the manufacturability side, it means making slots, holes, fixtures and complex shapes to integrate all of the technology. Since the only option for making this product tangible is injection molding it also means that variety of inserts will be used to form these complex features and that the moldability optimization also should be implemented. Micromolds℠ is driven by such challenges daily and that is what we love about on-demand molding business. We are proud to be chosen to fulfil “TeltoHeart” smartwatch prototyping phase needs from design optimization and consultation to actual physical prototypes. “The company was contacted due to their flexibility and short lead times, also because their other manufactured products proved to be high-quality. We need a flexible and reliable partner that can produce on-demand quantities. They are the perfect partner as they own the injectors that warrant our initial quantities.” Inserts made with metal 3D printers The watch strap had to be mounted to the plastic case at a particular angle which made mold machining nearly impossible. Luckily, metal 3D printing technology could be used for that. Metal 3D printing technology is based on laser power which binds small metal particles in requires geometry. Layer by layer 3D printer made the inserts which were successfully installed inside the molds. Not only have 3D printed inserts been used but also the sensors and metal connectors made and designed by Teltonika Telemedic team. It was quite a challenge to fit them all in such a tiny plastic case which meant placing every insert inside the mold at specific positions with an extra high precision to avoid any defects like flashes or unwanted weld lines. The watch strap Rubber, silicone and elastomer – all three different chemical materials but very similar for a regular user. When looking for material for a watch strap two main challenges arise immediately. The first being the resistance to wear and the second being the tackiness. Not only the material will have to maintain its form while being twisted, bended and stretched but also not to collect dust and feel comfortable. “Originally, we wanted to explore ideas using silicon bands, but silicon does not provide the durability and properties that are offered by TPUs” – says Jostautas Petrusevičius, Hardware Engineer at Teltonika Telemedic. Huge amount of TPEs’ combinations was tried to obtain the desired feel on the skin. The strap also had to be hypoallergenic and withstand sterilization even with corrosive liquids like isopropyl alcohol. When it seemed that the right material has been found there were always one more thing to remember - “TeltoHeart” smartwatch strap will have an integrated sensor. Such integration is one of its kind in the whole smartwatch industry and this is one of the reasons why Teltonika Telemedic team has also consulted with our company. Such feature demanded an extraordinary technology. How to insert such a sensor in a flexible elastomer strap which would resist fatigue and other environmental harsh conditions over time. Elastomer overmolding came as perfect solution. While overmolding itself is not something new we have been doing, in this case we had to overmold the flexible (floating) wire inside the strap. Even though injection pressures are not high but it can still deflect the wire inside the strap which would result in wire being not fully overmolded. Despite this difficult challenge our team succeeded in a uniform wire overmolding. The results “We are really satisfied with Micromolds ℠ services. The company offered fast and responsive technical support. It helped us to save time and expenses on expensive tooling for mass production. We could see and test possible problems before mass production and eliminate them.” The quote above summarizes it all. We are so happy to share this story which once again proves that our hard work pays off. We can deliver results and we truly help companies to innovate and this is the biggest reward we can get.

  • Injection molding of an AirTag Holder – plastic case with overmolded bushing inserts.

    SUSHI Bikes GmbH It is not the sushi you may instantly think of. It is an e-bike that was developed and designed to cut an average e-bike cost by half - to just 999EUR. SUSHI bikes is a young growing start-up company disrupting e-bikes industry by taking not only a green approach to the mobility and the future but also to the manufacturing and sourcing of the bike’s components. How otherwise they could cut those costs so considerably without losing bikes’ quality? Since here at Micromolds not only do we cut molding costs twice too but we also help companies to fill the market gaps caused by demand fluctuations and bridge manufacturing from low to medium size production. We believe that our cooperation with SUSHI bikes very much relates with their overall objectives. This time we helped this company to develop and manufacture an AirTag holder which can be easily attached underneath the saddle. Design for manufacturing (DFM) As every molding project begins with DFM this was no different and we immediately started moldability analysis and part optimization for injection molding. Mainly we did these changes: 1. Draft angles have been added to the parts. 2. Some areas have been hollowed out to make walls of uniform thickness. This was done to prevent certain areas from sink marks, voids and distortions. Nevertheless, there were still remaining some places where we could not make a uniform wall thickness without changing the part’s geometry. So, we ran a moldability analysis and images were provided to see which places might be at risk of having those defects. 3. Logo has been extruded out instead of cut out to enable surface finish on flat surfaces. 4. Some walls have been pushed inside 0.5mm because of impossible mold construction. 5. Some fillets were removed around the round surface because of impossible mold machining. 6. Visuals were provided to depict: parting line, injection points and locations of ejectors. Overcoming the sink marks Thanks to our smooth communication with the SUSHI bikes’ mechanical engineer Max, we had an opportunity to exchange our know-how and thus we came up with a slight design changes to reduce those sink marks marked in red. The hollowing of thick wall region was a great balance for not losing a contact surface area in the assembly but also decreasing a sink region considerably. Mold making It took us exactly 8 days to machine the molds after the DFM was confirmed. We used aluminium molds for this low-volume production batches. Polishing was required of outer plastic casing surfaces, however, machining marks were left for the inside. Both sides of the plastic AirTag holder fit in two separate micro molds having 1 cavity each. Overmolding vs press fit When we were asked to also do the assembly of the plastic housing we were thinking of using a press to tight-fit the bushings. However, only after several days, still in the initial stages of the project we agreed that overmolding will be more effective solution. We had to do slight modifications to the mold during the DFM but therefore we could save assembly costs and time considerably. Injection molding, the assembly and packing We were happy that we could provide end-to-end service for our client. After samples were confirmed we finished the first batch of 1000 units in a few days. We did the manual assembly of the whole batch. We also stuck EAN code labels to the packing boxes that were provided by the client and successfully delivered project on time. In the end, What does this really have to do with the Japanese speciality - sushi? “One rolls, the other are Rolls. So who doesn't immediately think of SUSHI when they think of e-bikes?” - SUSHI Bikes - this is how we roll.

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  • Micro Injection moulding | Europe | Micro Components

    Micromolding precision parts GET A QUOTE We specialize in micromolding technology across variety of industries . State of the art services for micron-scale parts - 100% in-house Common Applications: Why us? Healthcare​ Micro-optics Micro-electronics Micro-mechanics Microfluidics Micro materials ​ 10 years of experience Consultation Material selection Engineering grade plastics Vast variety in stock We do our best to guide our clients across jungle of material choice. We have 10 years of experience to share with you. Material choice is one of the first things to consider when designing new micro part because all main design constraints will continuously will refer to the resin chosen. Please use our materials guide for correct plastic selection. ​ ​ Micro design ​ Thin walls ~150µm Edges ~25µm Holes ~50µm Radii ~5µm Micro part does not have to be microscopic to qualify for micromolding. Controversially, larger parts with micro features are even more complex to mold. We are capable of designing and molding micro features as small as: ​ Thin walls ~150µm Edges ~25µm Holes ~50µm Radii ~5µm ​ ​ Micro-tooling ​ CNC precision machining Precision of microfeatures <5µm Sarix MACHline micro EDM machining Aluminum molds - 2x faster and cheaper Up to 200 cycles - ideal for launches Extraordinary EDM and CNC precision machining is used to manufacture molds that posses micro features. We are able to reach the precision of <5µm. We use Sarix MACHline micro EDM machining. Making good tool means molding precise and quality parts and this is what we strive for. ​ ​ Failure Modes and Effects Analysis 0-faults and errors ISO class 8 clean room ISO 9001 standard procedures Quality, assembly, packaging Right from DFM stage our engineers use Failure Modes and Effects Analysis (FMEA) to launch new production batches with 0-faults and errors. Quality checks are done on random parts by using high or low tech. All packaging and assembly is performed in ISO class 8 clean room. Variety of secondary services are provided: quality checking, custom packaging and labeling. ​ ​ Ready to start? 2 3 Analysis 1 day 4 Optimization 1-4 weeks Get quote or call from our engineer Once an order is placed manufacturing begins Manufacturing 2-4 weeks DFM anlysis Place an order Shipping parts Parts are shipped UPLOAD CAD FILE 1 Upload CAD file or describe your idea GET STARTED Our experience '' Great services with quick response time. Jonas is not afraid of innovative solutions which is a great asset when trying to make high quality products! '' '' Great work! Jonas with his team helped us directly while developing a new hardware product. Our demands were understood and delivered as our mechanical engineers imagined. '' Still curious? What is micromolding? When we speak about moulded plastic parts weighing a fraction of a gram we probably enter micro injection moulding boundaries. To define micro moulding it is good to have in mind that tolerances for microfeatures vary from 50µm to 5µm. There is no surprise that such precision parts are widely used in medical and dental industries - a lot of surgical instruments in these fields are invasive. To mould such micro components complex mould machining tools and methods are required, as well as custom configurations of precision plastic injection machines because for micro parts, shrinkage management is even more sophisticated. On the other hand, precision moulding basic principle is the same as conventional injection moulding - liquified plastic is injected in mould cavities. Other applications Micro-optics and microfluidics are the fields in need for micro plastic parts also. Small optic devices which are minimally invasive surgical tools require high precision plastic parts with micron-level tolerances. Overmoulding and insert moulding is also possible at micro scale. You can find more information about overmoulding and insert moulding here . Packaging Packaging comes as a latter priority when talking about manufacturing. However, when working with such small scale parts it can become first priority as failure in automated packaging can lead to failure of the whole project. Wide range of secondary services might be performed to complete this stage successfully. Here at 'Micromolds' we take this step seriously and ensure smooth production, packaging and shipping to our clients. ​ Materials ​ Almost any polymer you can find in the world can be used for conventional injection moulding. However, for high precision mouldings special materials might be needed. Please visit our material's page to find out more about choosing right engineering-grade compounds. ​ Micro tooling - mold machining ​ Precision parts are made with precision moulds. We design micro parts and their moulds independently and locally right from product idea to G-code and machining. For micro components machining of the mould gets really tiny and the challenges like controlling part shrinkage and managing draft angles makes mould machining much more complex than usual. However, the distinction line between micro moulding and the so called 'macro' sometimes seems to disappear as larger parts still can fit in micro mould but have high resolution features. At "Micromolds" we define 'micro' as when the part size is less than 1g or/and it has micro features (like microfluidic channels) or/and it has dimensional tolerances from 50µm to 5µm. Currently we are capable to machine with as little as 0.2mm milling cutters, thus achieving minimum inside corner radii of 0.1mm and to maintain +/- 0.005mm tolerance. We are also able to have 5:1 or 10:1 length-to-diammeter ratios. Moreover, for extremely small features we can push forward our maching limits with EDM machining. ASK A QUESTION What other services might you need? Insert Molding Insert moulding is the process when components (e.g. wires) are encapsulated ​ READ MORE Small Parts Molding 'Micro' is not always 'micro'. If your part can fit in your hand - mold it 2x faster and cheaper with us. ​ READ MORE Medical Injection Molding Microfluidics, OEM solutions, clean room 8 molding, sterilization and medical grade plastics. READ MORE Explore further Micromolding - in-depth Insights ​ ​ Rapid Injection Molding Contact an engineer Tel: +370 634 44885 Lentvario str. 16, Vilnius, Lithuania, 02300

  • Blog | Micromolding

    Blog ​ Your blog feed for industry 4.0 manufacturing knowledge base, in-depth insights, and expert opinions. 7 days ago 6 min An Overview of Micro Mould Manufacturing Micro mold manufacturing is a critical step to guarantee high-precision injection molding 0 comments

  • Success Stories | Micromolding

    Success Stories ​ Get to know about our latest projects and success stories with our clients. Step into our shoes and see the inner world of our daily challenges that we are constantly facing. masaitytieva Jul 3, 2021 4 min Success Stories Biodegradable Boule de Ferlette for MyCourant Our most recent micro injection molding project has allowed us to put our passions for challenges and sustainability. 0 comments Dominic Aug 5, 2020 2 min Success Stories Signed Sponsorship Agreement with Vilnius-Lithuania iGEM 2020 Team The iGEM (International Genetically Engineered Machine Competition) is the largest annual international competition in synthetic biology. 0 comments Dominic Aug 5, 2020 3 min Success Stories 3D Printed Head Frame for Stereotactic Surgery The main idea of this project was to propose a new, more reliable and comfortable device helping to locate stereotactic arc more precisely. 0 comments Dominic Aug 5, 2020 1 min Success Stories Injection Molded Kitchen Cabin Spacer Sub-contracting our company may be very beneficial for such companies like "Reform" 0 comments Dominic Jul 28, 2020 3 min Success Stories Wire overmolding and successful button mold at first attempt Our team has been working together with "Brolis Semiconductors" company in several projects. 0 comments Dominic Jul 28, 2020 2 min Success Stories Plastic spacer and cover for COVID fighting UV lamp "Deeper" company is making world's first shore fishing wireless and smart echo sounder sonars. 0 comments Dominic Jul 18, 2020 2 min Success Stories Plastic Case Design and Manufacturing of a Vehicle Tracking Suite „Ruptela“ - one of the fastest growing high-tech companies in Lithuania, providing transport management solutions. 0 comments Dominic Apr 19, 2020 3 min Success Stories Plastic Injection Moulded Battery Control System Case We halved the tooling costs and time to market in respect of traditional plastic injection moulding. 0 comments Dominic Jan 11, 2020 3 min Success Stories Prototype of a Swimming Sports Tracker One of the biggest challenges in housing design was insulation and water resistance at high water pressure. 0 comments

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