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In combination of micro machining, laser and LiGA technologies we make molds that shape micro geometries you need. Your custom micro components molded with a synergy of modern technologies - micromolding In combination of micro machining, laser and LiGA technologies we make molds that shape micro geometries you need. GET AN OFFER Experts in micro injection molding Explore our recent projects across the industries and see a backstage of true micro molding technology. "We received parts with perfect Part-to-part or lot-to-lot consistency." READ MORE Patent pending technology - glass molds for your sub-micron features We use Nickel and Silica inserts that are precision machined and installed to our micro moulds. Laser ablation Selective Laser Etching (SLE) Multiphoton polymerization LiGA (Nickel plate inserts) Fill micro cavities with variothermal and vacuum molding Successful micro tooling is just a halfway. We use variothermal and vacuum molding to overcome polymer melt flow hesitation effects and fill thin walls Thin walls as thin as 0.1mm Through-holes with a diameter of 0.05mm Micro features as small as 0.02mm High aspect ratios of 1:10 Tolerance control at every stage of micro-molding By controlling tolerances at every stage of injection molding, we can achieve high levels of quality and consistency . 4µm (mold making) + 10µm (molding) + 4µm (metrology) + 2µm (material) ―――――――――――――――― 20µm (total) Optical metrology - a must for micro molding quality control When there is more deviation in the measurement than in the actual molded part, quality control is even more challenging. Immediate dimensional check in molding process Guarantee the consistency and repeatability of micro-molded parts Verify the intended design specifications Contact an Engineer info@micromolds.eu Tel: +370 634 44885 Nalšios g. 11, LT-14332, Vilnius

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 and, hopefully, overcoming. 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. ASK A QUESTION Injection Molded Plastic Housing for 1 Channel EMG Sensor The company specializes in robotic hand prostheses end-to-end development and production. Since 1998 Company continuously and patiently... Success Stories Scarlet Grey Aug 16, 2022 3 min read "Allergomedica" Uses Moulded Plastic Cases to Enable Health Tests Kits at Home The Allergomedica (UAB Imunodiagnostika) clinic is an innovative place where not only comprehensive and professional help can be provided... Success Stories Dominic Jul 25, 2022 2 min read Uniweb Chooses Micromolds to Mould Grip Testing Device for Geriatrics We used aluminium mico molds for the mold core and cavity and steel for the precision inserts. Success Stories Dominykas Turčinskas Jul 21, 2022 2 min read Injection Moulded Plastic Chips for Droplet Microfluidics Droplet Genomics is a bio-tech company disrupting new ground in high performance analysis technologies. Success Stories Dominykas Turčinskas Apr 25, 2022 2 min read How Micromolds help Teltonika save time and costs when launching new products Teltonika Telemedic almost two years ago initiated an innovative smart watch development project in the telemedicine industry. Success Stories Emilijus Šližauskas Apr 21, 2022 4 min read Injection molding of an AirTag Holder – plastic case with overmolded bushing inserts. SUSHI bikes is a young growing start-up company. Wir dem Unternehmen bei der Entwicklung und Herstellung eines AirTag-Halters. Success Stories Emilijus Šližauskas Apr 12, 2022 3 min read MFI Medical Industrial Uses Micromolding for Electrode Plasitc Housings This cooperation itself was about injection moulding of a plastic housing for the electrode. Success Stories Emilijus Šližauskas Apr 8, 2022 3 min read Medical Device Moulding – A Test Tube with Moving Components and Membrane Cap Rapid injection molded prototypes for innovative medical test tubes to fight Covid-19 pandemic. Success Stories Emilijus Šližauskas Apr 5, 2022 3 min read Biodegradable Boule de Ferlette for MyCourant Our most recent micro injection molding project has allowed us to put our passions for challenges and sustainability. Success Stories masaitytieva Jul 3, 2021 4 min read 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. Success Stories Dominic Aug 5, 2020 2 min read 1 2

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 and, hopefully, overcoming. Micro Milling Microfluidic Chips Creating microfluidic chips is a difficult and precise process. Manufacturers have several options available for creating small channels,... Dec 5, 2022 4 min read Microinjection Molding Challenges The need for tiny, even micron-scale parts has increased over the past few years, and thus the relevance of micro technologies is... Nov 11, 2022 4 min read Molded Plastic Parts Surface Textures Texturing (also referred to as engraving or graining) is the procedure through which you add a pattern to the mold’s surface. Doing so... Sep 22, 2022 5 min read Injection Mold (Tool) Modification Process Before you start the mold injection process, you need to consider potential modifications. Due to the subtractive nature of mold... Sep 22, 2022 5 min read How to Reduce Injection Molding Costs Even though injection molding is a cost-effective mass production method, it does involve expenses that can add up over time. At some... Sep 13, 2022 4 min read Injection Molding Surface Finish How a product looks and feels can make a world of difference to its value. That’s why choosing the right surface finish for injection... Sep 13, 2022 4 min read Injection Molding Wall Thickness In injection molding, wall thickness is one of the most crucial design elements. Selecting the appropriate injection molding wall... Sep 2, 2022 5 min read Injection Mold Design Basics The injection molding process allows manufacturers to rapidly create parts. The process involves using a mold into which a melted... Aug 31, 2022 5 min read Injection Molding Flow Lines Injection molding is a precise process, meaning many things can go wrong. Everything from operator error to minor issues with the mold... Aug 26, 2022 5 min read Injection Molding Sink Marks Even minor errors can cause physical defects in a part during the injection molding process. These defects may damage the part’s... Aug 25, 2022 5 min read 1 2 Blog Your blog feed for industry 4.0 manufacturing knowledge base, in-depth insights, and expert opinions. ASK A QUESTION

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 and, hopefully, overcoming. News Read about our latest activity across manufacturing industries and clusters ASK A QUESTION Company Arginta visits Micromolds Arginta Group originates from the Lithuanian capital private limited company Arginta with the lifetime dating back to 1991. Promising... Dec 7, 2022 1 min read Laser & Engineering technologies cluster (LITEK) meets Micromolds Laser & Engineering technologies cluster LITEK was established in 2010 but cooperation between science and SMEs continues for more than... Dec 7, 2022 1 min read Clusterisation in action This week we had guests of Directors of the Alliance of Lithuanian Clusters. On the meeting agenda was Lithuanian clusters future and... Nov 24, 2022 1 min read Delegation from Finland Nov 11, 2022 0 min read Micromolds becomes member of Cluster of Manufacturing Innovators (CoMI) During the meeting cluster members discussed on the cluster future strategy 2022-2024. The meeting agenda: goal of the cluster, value... Aug 17, 2022 2 min read

Read in-depth reports about plastic products manufacturing and micromolding technology. Get knowledge on product design and optimization, digital manufacturing in injection molding sector and grow with us together. Knowledge Base Read in-depth reports about plastic products manufacturing and micromolding technology. Get knowledge on product design and optimization, digital manufacturing in injection molding sector and grow with us together. CONTACT US Micromolding - in-depth Insights As most of modern devices are either getting smaller or requiring tinier components, the demand for plastic micro molding continues growing. Thus it is easy to guess - this article is going to dive us in peculiarities of micro injection molding technology. Cost of injection molding (includes calculator).xlsx This paper is for those who really want to understand why injection molding might be so expensive and how injection molding companies deduct their service pricing. The purpose of this piece is to take out the anxiety burden of sales engineers to tell the project cost when unprofessional RFQs are received, as well as an opposite side’s inconvenience to tell or not to tell the budget of the project. Rapid Injection Molding In today fast-moving world companies have to deal with high market speeds. 'First to market wins' is still a prevailing notion. Rapid injection molding distinguishes itself from traditional injection molding mainly in respect of tooling and digitalization. Overmolding The paper dives into details of overmolding (in both: conventional plastic injection molding and micro injection molding), reflects technologies used (insert molding, two-shot molding, low-pressure molding) and discusses benefits, applications, complexity, and innovations of overmolding. Mold cavity Mold cavity is one of the most important elements in injection molding and has a huge impact on the structural design of the molded part which must be impeccable for manufacturing process to proceed as stated in the project. This article introduces to the injection molding process for different types of cavity molds, their advantages and disadvantages, as well as the cost of injection molding. Injection Molding Prototyping In depth insights on the topic of prototyping for injection molding, reflecting the concept of injection molding prototyping itself, its relevance and process explained. Insert Molding Insert molding is a single-shot injection molding process highly applicable in manufacturing across many (e.g., medical, electronics, aerospace) industries. Even though insert molding seems to be very similar to overmolding, these two injection molding technologies differ and have their own benefits and drawbacks. Injection Molding Dilemmas: Hot or Cold Runners? One of the most common Injection Molding Dilemmas is how to make a right desicion whether to use Hot Runner Systems or Cold Runner Systems. This paper dives deep into the details of both systems and advises on how to make the best choice between hot and cold runners. Injection Mold Making: Types of Molds A mold might be the most important (and expensive) tool used in plastic injection molding. This paper explores the two main types of molds: aluminum molds and steel molds and explains the process of mold making and the most relevant things to consider. Design for Manufacturing for Injection Molding Design for manufacturing (DFM) refers to a process that optimizes the design of a component to make it less difficult to manufacture, cheaper, and more convenient to deal with. As design for manufacturing encounters the early stages, it is easier to optimize the product and reduce unnecessary steps and costs.

Insert Injection Molding is a single-shot injection molding process highly applicable in manufacturing across many (e.g., medical, electronics, aerospace) industries. Even though Insert Molding seems to be very similar to Overmolding, these two injection molding technologies differ and have their own benefits and drawbacks. Insert Injection Molding Injection Injection Molding is one of the most famous manufacturing processes that can be further divided into specific categories like overmolding and insert molding . Insert molding alludes to an injection molding process that helps in encapsulating a component, such as an electronic component of a circuit board or cable, into a plastic part. Before the molding process, the component gets loaded into the mold, and then molten plastic is injected into the mold. Once the plastic solidifies, the component in the mold gets lock into the plastic. Usually, thermoplastic resins or polymers, along with low-pressure molding techniques, encapsulate components into plastic packing. Like many other injection molding processes, the application possibilities of insert injection molding are seemingly diverse or somehow endless, from manufacturing simple (couplings, knobs, and filters) to complex (electrical components) parts. Because of the massive array of applications associated with insert molding, a wide range of industries are open to streamlining this process, replacing other conventional modes of injection molding. Apart from this, inserts are of different types, which get used for fastening and locating plastic parts with other assemblies. It is also likely to have variations of different inserts on a single part. Here is a list of the most common insert applications: dowel pins, spring-loaded clips, male thread, female thread, and electrical contacts. Table of Contents: Differences Between Overmolding and Insert Molding: Processes specifics Speed of Injection Molding Costs Benefits of Insert Molding: Assembly Cost Reduction Material Cost Reduction Flexibility and Reliability Assurance Insert Molding Application across Industries: Medical Industry Electronics Aerospace Industry Conclusion Anchor 1 Differences Between Overmolding and Insert Molding The general concept of insert molding and overmolding is quite similar ; however, there is a considerable difference between these two processes. Typically, overmolding is a dual-step process in which two separately molded parts get joined to enhance and improve the product's quality and features. Two parts are permanently joined to each other but do not involve complete encapsulation. Let us now understand the difference regarding processes, speed, and cost: 1. Processes Specifics The processes have many similarities but are still not identical. For example, in overmolding, a plastic component gets manufactured using injection molding . After it gets cooled, the component is placed into an overmolding tool and then coated with molten resin or thermoplastic. On the other hand, insert molding uses a pre-formed part , often metal. The part is manually loaded into the mold and overmolded by molten resins or thermoplastics. That is how insert molding offers complete encapsulation of molded parts, and two molded parts get molded simultaneously. Anchor 2 2. Speed of Injection Molding As far as overmolding is concerned, it involves an aluminum mold with no heating or cooling lines running through it. Nonetheless, the cycle time is a bit longer, allowing molders to ascertain the essential quality of parts, cosmetic concerns, and pressure. When all the molded parts get joined, the overmold tooling is assembled to press. Thus, overmolding is more time-consuming than insert molding. At the same time, insert molding is a comparatively faster and quicker process. As two plastic materials get molded simultaneously, the time taken is low. In addition, the process requires less arrangement if compared to overmolding, which also reduces the time. 3. Costs Overmolding is a double-shot process, while insert molding is a single-shot process. Though both techniques are of lower costs, insert molding is a bit cheaper than overmolding. The reason is that it eliminates secondary assembly operations, including gluing, snap fits, screws/fasteners, etc. Benefits of Insert Molding The trend of insert molding is rapidly growing among the manufacturing industries. Wide range of applications, lower costs, and simple process; all these factors add to make the insert molding process convenient for manufacturers. Here are some most familiar benefits of insert molding: 1. Assembly Cost Reduction Insert molding is a highly cost-effective manufacturing process. The foremost reason behind this is that it is a single-shot process only . Therefore, the need for post-molding assembly, which usually happens with the separate metal element, gets eliminated. Similarly, separate parts installation adds in demand for labor, includes motion waste, and requires more production time and additional equipment & functions. But then again, all these arrangements are not more needed in insert molding. Hence, these are the reasons that justify the lower costs of insert molding. 2. Material Cost Reduction As discussed earlier, overmolding is a double-shot process in which the plastic part is molded and then overmolded. That is how the size and the final product's weight are comparatively heavier than the final product achieved due to insert molding. While being a single-shot process, insert molding brings down material costs and makes the material wastage almost negligible. Consequently, like the micro injection molding process, the reduced weight and wastage, smaller size, and lower manufacturing time reduce the costs of the insert molding process. 3. Flexibility and Reliability Assurance Insert molding provides considerable flexibility and reliability assurance . For example: It empowers designers to add features to plastic parts, making them more grounded, sturdier, and more reliable than local plastic areas. It offers improved product design by incorporating features impractical with plastic alone. It is helpful in metal to plastic transition to make parts more proficient – decreased weight, reduced production expenses, and eliminated corrosion. Anchor 3 Anchor 8 Anchor 4 Anchor 5 Anchor 6 Anchor 7 Anchor 9 Anchor 10 Anchor 11 Insert Molding Application across Industries Being cost-effective, faster, reliable, and flexible, insert molding offers many applications across different industries. Along the same lines, here are some of the common industries in which insert molding plays the most influential role: 1. Medical Industry Health and care sector is hugely relying on products manufactured using insert molding process. Ranging from simple devices to intricate and sensitive devices like delivery equipment for stents, sutures, and implants, all medical devices manufacturing is being done using insert molding . Besides, electronic devices with excessive use in the medical industry involve certain parts manufactured using insert molding. The most common products of insert molding include: Medical Knobs. Medical Enclosures. Tubes. Medical equipment component. Prosthetics. Blades and surgical instruments. Dental instruments. 2. Electronics Like other industries, electronics industry is finding the use of insert molding beneficial . Encapsulation of wire plugs and threaded inserts in molded parts are typical examples of insert molding applications in the electronics field. Electronic industries are well-convinced over insert molding instead of working with assemblies and using solders and fasteners. Accordingly, the following are the typical applications of this type of molding in the field of electronics: Digital control panels, assemblies, and knobs for appliances. Threaded fasteners. Encapsulated electrical components and devices. Military equipment. Encapsulated brushings. Anchor 12 3. Aerospace Industry The typical applications of insert molding in the aerospace industry include seating of aircraft, stowage bin latches, handles, lavatories, and user interface switches. The key advantages of insert molding in the aerospace industry include: Decreased weight of aircraft. Increased durability and strength. Elimination of additional and undue assembly and manufacturing steps. Reduced assembly time and manufacturing time. Improved and enhanced industrial design. Anchor 13 Conclusion Insert molding is one of the influential and famously adopted molding methods. The reliance of diverse industries over the manufacturing of specified products massively belongs to this manufacturing process. Typically, overmolding and insert molding are commonly considered identical processes; however, there is a clear difference between them, as mentioned above. As far as the global market size is concerned, according to the verified market research, the global insert molding machine market is growing substantially, and the market would significantly expand from 2019 to 2026. In short, insert molding holds a better capacity to fill up the modern needs of industries, which is the very reason for expanding its use. Table of Contents: Differences Between Overmolding and Insert Molding: Processes specifics Speed of Injection Molding Costs Benefits of Insert Molding: Assembly Cost Reduction Material Cost Reduction Flexibility and Reliability Assurance Insert Molding Application across Industries: Medical Industry Electronics Aerospace Industry Conclusion Back to Top Explore our services: 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 Micromolding Micromolding begins when microfeatures take place and vary from 100µm to 5µm in size. READ MORE Medical Injection Molding Microfluidics, OEM solutions, clean room 8 molding, sterilization and medical grade plastics. READ MORE READ MORE READ MORE

A white paper on mold cavity explaining the most important concepts regarding mold types in injection molding as well as cavity pressure and its measurement, mold cavity space, shape and shrinkage. Mold Cavity Mold cavity is one of the most important elements in injection molding and has a huge impact on the structural design of the molded part which must be impeccable for manufacturing process to proceed as stated in the project. This article introduces to the injection molding process for different types of cavity molds, their advantages and disadvantages, as well as the cost of injection molding. Table of Contents: Injection molding process Types of molds in injection molding Cavity pressure measurement Cavity pressure sensors Mold cavity space Cavity shape and shrinkage Anchor 1 Injection molding process Injection molding technology is used for mass production and it takes an excessive amount of time for manufacturing, thus it is essential for the process to be as rapid as possible. This could be done by ensuring excellent technical properties of the machinery. Therefore, determination of how the plastic will be injected into the mold is a must. The mold consists of the cavity and the core. The process of injection molding starts with placing raw materials (usually in pellets) into a molding machine. Then, through nozzles, the material is being shot into the mold through the injector gate and, lastly, reaches the mold cavity. Cavity is attached to the fixed side of the press while the core is on the moving side of the clamp. In other words, the core makes the internal shape and cavity is the external shape of the part. After the plastic reaches right place, the cavity and the core close and allow the part to cool. Later the core is being pulled out and the component ejected. Types of molds in injection molding Even though the main concepts may be generalized, the process of injection molding may differ depending on the types of mold cavities. There are three main types of molds used in injection molding: Single cavity molds. These molds produce a single part per cycle and are mainly used for micro injection molding when low-volume production is demanded. The machinery for single cavity molds is lighter and smaller, therefore, results in reduced tooling costs and waste minimization. Accordingly, single cavity mold injection molding is usually quite cheap to perform, however not that efficient and thus not widely applicable for mass manufacturing. Multi-cavity molds. The main difference between single and multi-cavity molds is that multi-cavity molds have more than one cavity. Logically, this allows to scale the production and manufacture more parts through a single cycle. Multi-cavity molding increases productivity and enables more efficient use of resources. This type of manufacturing is rather expensive compared to the single cavity molding due to higher machining costs. However, if used for high-volume production, it minimizes price per piece while maximizing efficiency. Family injection molds. This type of molds, as multi-cavity molds, has more than one cavity cut into the mold and several parts are formed from the same material in one cycle. As each cavity may form a different component, family molds are an ideal choice for prototype molds. In this way, not only the processes are more efficient, but also much simpler. Anchor 2 Cavity pressure measurement Cavity pressure is one of the key parameters indicating the quality of the micro molded components , as the sensor indexes the pressure in the mold which overpowers the polymer melt resistance and pushes it into cavities. Then the hot runner systems may be controlled along with the cavity pressure measured. The cavity pressure is usually calculated by the formula below and actually measures pressure per area: Cavity pressure (P) = 400 kgf/cm2 Cavity pressure sensors Specific observations on cavity pressure are made by using cavity pressure sensors that are most usually placed along the polymer melt flow paths to convert the pressure into the measure of the piezoelectric effect. There are two main types of cavity pressure sensors : Direct cavity pressure sensors are directly inserted into the measurable area. Under pressure, a sensor delivers an electrical signal in the pC (Picocoulomb) units and then converts it into pressure units which indicate change in pressure divided by Picocoulombs (bar/pC). Indirect cavity pressure sensors , also called force sensors because pressure is caused by force through ejector pins, are placed outside the cavity, usually behind the ejector pins. Indirect sensors are sensitive to a change in force. Therefore, similarly to direct, indirect sensors transmit electrical signal (pC) after change in pressure, but in comparison, they turn the measurement into change in force units divided by Picocoulombs rather than change in pressure units. Mold cavity space Mold cavity spacing is of great relevance when optimizing injection molding processes. Minimizing mold cavity space may lead to a significant cost reduction due to the following reasons: Retainer plates are less needed to support the nozzles Operating costs decrease because lower cavity spacing prevents the heat loss and nozzles and manifolds connection on the surfaces Mold cavity spacing minimization shortens the injection cycle because the heat is removed faster. However, even though due to mold cavity spacing minimization the processes are cheaper, they might become ineffective. The reason for that is that the surface temperature differences (when cooling) may negatively affect the quality of the components, especially if the component parts cool differently due to uneven wall thickness or deformation which sometimes might be caused by attempts to minimizing mold cavity spaces. Anchor 3 Anchor 4 Anchor 5 Anchor 6 Cavity shape and shrinkage While solidifying, the volume of the molten plastic in the cavity tends to shrink because of the variations of polymers density between melt and rigid stages. Sometimes a warpage may occur - if some parts of a component shrink and cool unequally, this might lead to component deformation and defects. Both equal and unequal shrinking and deformation have the same impact on mold cavities. Shrinkage is signified as a rate and is a crucial indicator in material choice because different materials shrink differently and have specific intervals of allowance. Most usually, the interval has a range between 0.2% and 2%. Not only is shrinkage dependent on material, but also on other factors, such as temperature, duration under pressure, wall thickness, the shape of the gates and additive materials (if present). Back to Top Table of Contents: Injection molding process Types of molds in injection molding Cavity pressure measurement Cavity pressure sensors Mold cavity space Cavity shape and shrinkage Explore our services: 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 Micromolding Micromolding begins when microfeatures take place and vary from 100µm to 5µm in size. READ MORE Medical Injection Molding Microfluidics, OEM solutions, clean room 8 molding, sterilization and medical grade plastics. READ MORE READ MORE READ MORE

By implementing micro design guidelines and best practices, we ensure functionality while minimizing component size . Our primary focus is on making your project manufacturable. Micro design Precise micro-sized components GET A QUOTE Micro design Simulating the micro parts Utilizing industry-leading simulation tools and practices, we optimize designs to enhance manufacturability . Simulation not only facilitates testing but also helps identify potential challenges early in the micro design and micromolding process. Materials - selecting the correct one We guide your team in choosing the ideal material for your component. The right selection impacts performance, durability, aesthetics, cost-effectiveness, and manufacturability, ensuring the product meets specifications and excels in its environment. Micro-sized parts require unique expertise. By merging our expertise in micro-scale product design with our manufacturing experience, we can optimize your designs and guide your team on the best design practices . The design optimization stage is crucial for determining the overall success of a project and offers the greatest potential for monetary savings . Micro design optimisation for manufacturing We streamline your product design for efficient assembly, reducing complexity and costs. Design for Assembly (DfA) Design for Manufacturing (DfM) We assist in refining products for simple, cost-effective manufacturing. READ MORE Design for Excellence (DfX) We help en hance your product's quality, functionality, and lifecycle value. Contact an engineer info@micromolds.eu Tel: +370 634 44885 Nalšios g. 11, LT-14332, Vilnius, Lithuania

We employ a variety of techniques to create precise micro-sized components. These methods not only reduce material waste but also enhance efficiency and quality CNC Micro milling Micro drilling Micro turning EDM (Electrical Discharge Machining) Laser-based microtooling processes Microtooling precision parts GET A QUOTE Microtooling Space-grade aluminum and steel We utilize high-quality materials, including space-grade aluminum and steel, to ensure durability and precision in our mold components alloy 545 alloy 5698 alloy 4535 We control tolerances at every point of microtooling When it comes to microtooling, we take meticulous measures to minimize imperfections in tolerances. Monitor the lifespan of every drill bit Implement temperature control systems throughout our facilities Employ professionally trained machining experts. These experts leverage their expertise during the mold manufacturing process to ensure the highest level of precision CNC with tool sizes as small as 0.1mm and utilizing both 5-axis and 3-axis machines EDM Micro drilling Micro turning Laser-based microtooling processes - laser eching Multiple micromachining techniques Polishing mold surfaces using both electropolishing and traditional polishing techniques Creating diverse surface finishes through sandblasting and EDM processes Laser etching to achieve any super-detailed surface texture you require Surface finish with any texture Our specialties Insert moulding is the process when components (e.g. wires) are encapsulated Overmolding 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 Contact an engineer info@micromolds.eu Tel: +370 634 44885 Nalšios g. 11, LT-14332, Vilnius, Lithuania

The paper dives into details of overmolding (in both: conventional plastic injection molding and micro injection molding), reflects technologies used (insert molding, two-shot molding, low-pressure molding) and discusses benefits, applications, complexity, and innovations of overmolding. Overmolding Table of Contents: What is Overmolding? Technologies used for Overmolding Benefits of Overmolding Overmolding Applications Across Industries Overmolding Process Complexity Overview, Equipment Needed, and Innovation Latest Innovations in Overmolding Conclusion Anchor 1 What is Overmolding? Overmolding is a process where a single part is manufactured using two or more materials in a combination to protect sensitive components or give a better look and feel to the final product. The first material is called substrate, which is covered by the second material - overmold. The covering materials are usually thermoplastics or elastomers. It is assumed that the reader is familiar with the basics of injection molding. If not hover on the topics below: Plastic Injection Molding Injection molding is a process of manufacturing diverse types of parts by injecting molten material into the mold. The raw material is fed into the heated barrel, where it gets molten and transferred to the mold cavity. Primarily, plastic materials are raw materials, so the process is also called plastic injection molding. Micro Injection Molding Micro molding is also a sub-branch of injection molding used to produce tiny, high-precision thermoplastic parts and components with tolerance in microns. Technologies Used for Overmolding There are mainly three technologies used for overmolding : insert or single-shot molding, two-shot or multi-shot molding, and low-pressure injection molding. 1. Insert Molding Insert molding, also known as single-shot molding, is the most generally utilized process in which a pre-molded insert is put into a mold and the TPE (thermoplastic elastomer) is shot over it. The benefit of insert molding is that it is a bit faster than conventional injection molding. The reason is that insert molding offers the molding of two plastic materials simultaneously. Apart from this, the tooling costs related to insert molding are also lower. 2. Two-shot Molding In two-shot molding (or multi-shot molding), complicated molded parts are produced from two unique materials, and the product reaches its final form in two related and subsequent steps. The molding machines consists of two or more barrels, and two materials are shot during the same cycle. The first material is fed to the barrel to create the first form of product, which then enters the second barrel for the final build. The advantage of two-shot molding is that the part quality is higher and labor costs are lower. 3. Low-Pressure Molding Because the electronic industry is growing continuously, so the need for electronic manufacturers to protect weak and fragile components has become imperative. Accordingly, low-pressure molding, developed by Hankel Corporation in 1970, started playing a vital role in the encapsulation of delicate electronic parts, replacing the need for traditional potting processes. This advanced encapsulation process of weak electronic components involves an overmolding process that is carried out using low pressure and temperature and involves less time. Anchor 2 With the increasing need for printed circuit boards (PCBs) and their protection, low-pressure molding has gained ground manufacturing components in automotive, medical, industrial, and lighting industries. A protective mechanism for LED lights can be considered as a glaring application of low-pressure molding. Benefits of Overmolding Overmolding process is consistently finding expansion in its use, along with the following benefits: 1. Reduced Assembly and Secondary Operations Costs While using overmolding for manufacturing parts, there is no need for secondary or additional operations. First of all, the overmolding process eliminates the need for extra adhesives and fasteners. Secondly, it does not need any further operation to get the product to its final form. All these factors hugely reduce costs, time, and the need for labor. 2. Improved Product Quality and Reliability Overmolding is a highly reliable process since the final product provides users with the ultimate convenience of rubberized and firm grip tools like handheld products and toothbrushes. Consequently, the ergonomics of the product get improved. The over-molded part has a protective layer of thermoplastic that makes it flexible, durable, and highly resistant against external forces. 3. Higher Flexibility of Design Manufacturing of multi-materials in a single of multi-colors and complex assembly design is easy to achieve with overmolding. Overmolding process ensures rigid assembly and proper alignment of mating parts. Therefore, the quality of the product and the requirement of seamless and compliant designs become easily achievable. Overmolding Applications Across Industries Overmolding has diversified applications across myriads of industries. Before moving to the specialized applications of overmolding, here are some of its generalized applications: Anchor 3 Anchor 4 1. Generalized Applications of Overmolding Cable assemblies are a magnificent application of overmolding. Cables manufactured using the overmolding process need to face high-pressure wash downs, extreme weathers, persistent sanitation, exposure to debris and dust, and frequent strain flexes. Other common examples of overmolding include military equipment, solar energy panels, medical equipment, consumer electronics, and diverse industrial applications. 2. Specialized Applications of Overmolding a) Medical Industry Medical injection molding has considerable applications in the field of medicine. Overmolded medical devices comprise rigidity and toughness of one material and an ergonomic and soft feel of other material. The flexible and sturdy exterior of molded parts reduces the chances for abrasion, protects the rigid substrate from any external impact, keeps user hands safe from an infusion of vibrations, and offers excellent water-resistant properties to save from corrosion. The over-molded medical instruments include: Handles of ambulance defibrillator Syringes Electrical connectors Lure fitting or tubing Monitors The market size for molded equipment in the medical field is $1.38 billion. It is expected to grow with a CAGR of 8.2% by the end of 2027. b) Automotive industry By now, overmolding is used to make prototypes, handles, accessories attached with dashboards, and molded parts under the car hood. Thermoplastic Overmolding for Structural Composite Automotive (TOSCAA) project has revolutionized the use of over-molded parts in the automotive industry. This consortium is headed by the SGL carbon fibers and Land Rover, Jaguar, Nifco, LMAT, AMRC, and the University of Nottingham. Collectively, all these partners have collected £2 million with the focus of making cars lighter, durable, and swifter. In 2016, the global market size of molded parts in the automotive industry was $1.67 billion and $3.29 billion by the end of 2025. c) Electronics Wire overmolding is one of the significant applications of overmolding in the field of electronics. Many parts in the electronics field are over-molded to make them durable, flexible, and shear resistant. However, insert molding is also excessively used for manufacturing a single part with the combination of two materials. PCBs, circuit boards, thermostats, and wires are widely put under the overmolding process to become strong against external factors. Electronic silicon overmolding is now opening new domains for further expansion of overmolding in the field of electronics. As indicated by some statistics, the market size of molded parts in the electronics industry would have reached $1.11 billion by the end of 2029. d) Toys The toys industry overwhelmingly relies on the use of plastic molded parts. The over-molded components used in toys provide the demanded safety against external stresses. Furthermore, a vast number of industries are using molded parts manufacturing following products: Dolls and action figures Models and crafts Electronic toys Nonelectric puzzles and games For example, Microplastic is a leading toy industry that uses molded parts to manufacture toys. It generated a revenue of $30 million in the past year. Anchor 5 Overmolding Process Complexity Overview, Equipment Needed, and Innovation Overmolding is a bit complex but easy-to-understand process. Along the same lines, here are some of the points to describe complexity overview, equipment needed, and innovation regarding the overmolding process: Complexity Overview Overmolding is a bit more complex than conventional molding. The first thing that makes it more complicated is the right choice of over-molded material on the substrate. At the same time, it also needs to be taken care of whether the over-molded part is sitting correctly on the substrate or not. Nonetheless, robot-work or machines are capable enough to eliminate all these concerns. If this job is done manually, all these apprehensions will remain the same. Characteristics of Molding and Inserting Inserting is a manufacturing process that combines two materials to make a single material, while molding is a simpler process that follows straightforward steps. The procedure of inserting and molding has already been discussed in one of the above sections. However, some factors make inserting and molding a hard-to-reach process, including flowlines, sink marks, warping, short shots, burn marks, and jetting. Anchor 6 Demolding Demolding is referred to as the removal of molded parts from die or mold. It can either be done manually or using compressed air. Eliminating a casting from a mold and a mold from a model is known as demolding. Demolding of the manufactured part might be a little complex if it is not adequately molded. Closing the mold and repeating the process is not a solution, and the component becomes a wastage. But then again, wastage is genuinely minor in the overmolding process as it uses calculated and pre-defined parameters like low pressure and temperature to encapsulate naturally weak components. Subsequently, overmolding yields less wastage. Similarly, the application of automatic demolding reduces manual effort. Latest Innovation in Overmolding Overmolding is evolving day by day, and its use is becoming more frequent due to the mainstreaming of the following innovations: Micro-overmolding in the field of the medical industry Overmolding electronic control units in the electronic industry Manufacturing of the flattest control unit with seven millimeters only Latest transmission control system Conclusion Overmolding has become a globally renowned and adopted method for manufacturing parts that are usually vulnerable to external stress. Using overmolding has expanded in every significant field like the medical instrument industry, automotive industry, electronic industry, and household product manufacturing industry. Although the process has certain complications, it is still the most appropriate way to protect weak and frail parts. Anchor 7 Table of Contents: What is Overmolding? Technologies used for Overmolding Benefits of Overmolding Overmolding Applications Across Industries Overmolding Process Complexity Overview, Equipment Needed, and Innovation Latest Innovations in Overmolding Conclusion Back to Top Explore our services: 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 Micromolding Micromolding begins when microfeatures take place and vary from 100µm to 5µm in size. READ MORE Medical Injection Molding Microfluidics, OEM solutions, clean room 8 molding, sterilization and medical grade plastics. READ MORE READ MORE READ MORE

This paper is for those who really want to understand why injection molding might be so expensive and how injection molding companies deduct their service pricing. The purpose of this piece is to take out the anxiety burden of sales engineers to tell the project cost when unprofessional RFQs are received. How to Calculate and Save Costs of Injection Molding (Includes Cavity and Molding Cost Calculator .xlsx) This paper is for those who really want to understand why injection molding might be so expensive and how injection molding companies deduct their service pricing. The purpose of this piece is to take out the anxiety burden of sales engineers to tell the project cost when unprofessional RFQs are received, as well as an opposite side’s inconvenience to tell or not to tell the budget of the project. Table of Contents: Infographic overview Starting with the basics Disclaimer Heading to the optimum Project and machine constraints Declaring a budget (off topic) Three main inputs Fourth main input - cavity number calculation Surface finish Sum up Dependent, independent, control values Injection molding cost calculation Raw material calculation Mold making cost calculation Production cost (molding cost) Whole injection molding project cost Optimal cost - what goes into the quote Micromolding - wining at small quantities What you will learn (an infographic overview): Infographic Starting with the basics It is assumed that the reader is fully familiar with the common injection molding definitions and procedures. If not hover on these topics: Basics What is injection molding? Injection molding is a serial production technology where molten thermoplastic pallets are injected in the molds. Cooled plastic solidifies and when the mold opens it is ejected as a brand new plastic part. Read more here . What is mold and tooling? Tooling is the process of mold machining. Mold is a 3D designed part ‘subtracted’ or carved out (milled) out of the block of metal (usually steel or aluminum). It is obvious that most of engineering know-how is condensed in this stage. Mold making is the core of injection molding technology and thus it has the biggest fraction of NRE cost. What is cavity and core? Since mold has two sides core and cavity take place in one or another. They are used to shape the injected plastic. In other words, the core forms the internal shape of the part and the cavity - external. It is worth to mention that by default cavity numbers can be distributed only in such a way: 1, 2, 4, 8, 16, 32, 48… This is because only than equal runner distances are possible for equal pressure distribution. Disclaimer This paper is used for understanding of the principle of injection molding pricing calculation. The examples given and calculations are simplified and may lack many factors which can change the results drastically as each project might have very unique parameters to include. Nevertheless, the paper is more than enough to familiarize customers with injection molding pricing method and is prepared for customization according individual needs. Heading to the optimum Just by a single look to the above infographic it becomes clear that estimating injection molding costs includes many variables. How not to get lost in this pile of varying factors and find the optimal solution for the buyer and seller – set an equilibrium cost/price correctly for both parties involved? As every mathematical problem or calculation should start with some reference point, this case is no other and the process starts with input variables setting. Project and machine constraints Disclaimer Heading to the optimum Project and machie constraints In this particular case it is assumed that the client needs are the starting point. The customer provides the RFQ where the huge chain of processes starts to move and impact each other. Ideally, reputable customer should provide his sub-contractors with this information: Production quantity interval Lead time interval Budget interval Part CAD drawings Material used specified Tolerances specified Surface finish specified Budget. Really? (off-topic) It seems that declaring budget interval might be the same as loosing bargaining leverage. However, experienced customers know that with complex projects, quotation procedure can be considerably prolonged just by molding company trying to provide budget A, B and C variants. For example, the budget can drastically decrease by eliminating automated inserts at the expense of a lead time or just by increasing molding cavities number (discussed further). So how the molding company should know what are the contractor’s preferences and future plans? Moreover, experienced customers always know the ranges of pricing and can always head towards budgets with buffers for bargaining. The point here is that, ideally, both client and service provider should seek for professional and transparent negotiations where quote is just a good starting point. Transparency in pricing should guarantee that project shareholders would seek for most efficient, win-win manufacturing processes and goal completions but not capital-only targets. Three main input values (back to-topic) Project constraints (information from the RFQ) let us deduce 3 main input variables: Production quantity interval (e.g. 20k-50k pcs.) Lead time interval (e.g. 1-2 months) Project cost interval (e.g. 1000-5000 EUR) It becomes intuitively clear that this initial input data should initiate the whole injection molding cost/price calculation – the molder has all information he needs: quantity, time and price range. However, to provide customer with an optimal quote, there is still one more important factor to evaluate. Fourth main input value (molding cavity calculation) The other RFQ’s 3 input values (part drawing, material, tolerances) are bounded by machine constraints and all these intertwined dependencies contribute to the next very important input estimation – quantity of mold cavities: budget Three main inputs Cavity number calculation 1. [Part drawings + material] -> [projected area + pressure] -> clamping force -> quantity of cavities A1 – projection area of 1 cavity and runner; Fn – required clamping force for n cavities; Fm – machine clamping force; f – coefficient (deduced empirically); Qn – cavity quantity (Qn = 1, 2, 4, 8, 16, 32, 48); Qmax – max. cavity number limit bounded by the size of machine. Constraints: Fn≤Fm; 1 PA1fQn Qn part volume -> shot size -> quantity of cavities V – part volume + runner volume Vmax – max. shot volume Qn – cavity quantity (Qn = 1, 2, 4, 8, 16, 32, 48) Qmax – max. cavity number limit bounded by the size of machine Constraints: QnV≤Vmax 1 plasticity -> quantity of cavities (e.g. 1-16) Determined experimentally. 4. Tolerances -> quantity of cavities (e.g. 1-16) Determined experimentally. The answer is 1-8 cavities Project constraints combined with machine constraints determine the forth value interval - molding cavities number. It should be clear that due to machine constraints the maximum molding cavity number is the minimal limit bounded by machine constraints (example above: 1-8). Why this is so important? Molding cavities number variation hugely affect budget of the project when manufacturing volumes increase, thus varying these total 4 input values together with molding cavities results in an optimal quote for the client. Surface finish – last but not the least Even though surface finish does not limit or affect cavity number calculation it becomes extremely important when tooling costs are calculated (discussed further). It is very important for the client to specify this as costs of tooling can be affected by 10-30%. Sum up By using customer’s provided data and machine constraints four main intervals of input variables were deduced: Production quantity interval (e.g. 20k-50k pcs.) Lead time interval (e.g. 1-2 months) Project cost interval (e.g. 1000-5000EUR) Molding cavities (e.g. 1-8) As the clients’ RFQs might not always be so informative or have even wider ranges to choose from it is the service provider’s responsibility to find and suggest the optimal quotation for the customer. To propose an optimal quote within these ranges when so many variables take place is not an easy task for injection molder. Surface finish Sum up Dependent, independent and control values NB! For the simplicity reasons, the lead time interval will be not included in the calculations. It is assumed, that every project is done as efficient as possible and at a full capacity and thus the projects will be completed as fast as manufacturing capacity can allow but no faster or longer than the customer requires. To put it simply, optimal in this case is that where minimum value is found of a function of several variables subject to a set of constraints. Yes, it’s going to be a graphical representation. As the molding cavity parameter is the only one which can vary it will be an independent variable (x-axis). As the most important result we are looking for is a project cost – it will be a dependent variable (y-axis) and for control values the production quantity will be set. Finally, the molding cost calculation and its relation to production volume and cavity number will be revealed. To do that, one should first understand that price of injection molding itself contains several components: Raw material costs Mold manufacturing (tooling) costs Fixed machine operating costs Other manufacturing costs (e.g. mold set up, post production…) These molding cost categories itself are also hugely affected by the primary input values: part drawings -> part difficulty -> tooling costs material choice -> raw material costs clamping force -> machine operating costs surface finish -> tooling costs etc. For every complex task ‘one bite at a time’ approach is always a good way to go. For better understanding please study and use this excel calculator of injection molding cost in parallel with this article: Raw materials cost Raw Material Cost vs. Cavities at Various Production Volumes Dependent, independent IM Cost Download Download Injection Molding Calculator .xlsx Injection molding cost Raw mterial costs Mold making cost At first sight graph data looks intuitively misleading. More cavities mean more material used, thus it appears that curves should slightly slope upwards. But when looking closer to the process of injection molding it becomes clear that more cavities means less shots too. This data shows that even though more cavities use more material, less cycles use lesser material, so in overall result the material used decreases when cavity number increases. Now it is a matter of runners’ geometrical parameters – whether the curves will be flattened or steepened. Mold making cost To understand the relation better you can download the excel calculator with the graph above (sheet2): Raw Material Cost vs. Cavities at Various Production Volumes Mold Cost Calculator ^ This linear relation of cavity number and mold cost seems to be intuitively clear. The production volume does not affect mold making price since molding itself does not correlate with volume up to the mold life time. Tooling, thus, is the minimal NRE cost to initiate the production at all. To estimate the molding cost various input data is needed: Fixed time to start (setting up the machine) Raw material cost Hourly machine and operators rate Machine costs per hour (depreciation or/and leasing) CAD design Fixed time per cavity machined (empirical estimation) Difficulty level (empirical estimation) Surface finish All these factors must be included to estimate the tooling price for injection molding. To play with input values and compare various prices use the excel calculator (sheet2). Production costs (molding costs) To understand the relation better you can download the excel calculator with the graph above (sheet3): Molding Cost vs. Cavities at Various Production Volumes Production Cost Production Cost Calculator ^ From the graph above it is possible to observe how hugely cavity number impacts manufacturing costs. To get such evaluation such input values were used: Cycle time for 1 cavity Prolonged cycle time per cavity (due to increase of injected material volume) Hourly machine op. rate Machine cost per hour (depreciation or/and leasing) Consumables and other costs per hour It is worth to pay attention to the cycle time here. While other input values more or less stay the same and are fixed for any project, the cycle time plays the major role in manufacturing costs. Thus it is very important to optimize the manufacturing processes as well as the parts itself to minimize the cycle time. To see how sensitive, the manufacturing costs are to the cycle time use the downloaded excel file (sheet3). Final injection molding project costs To understand the relation better you can download the excel calculator above (sheet4): Project Cost vs. Cavities at Various Production Volumes Project cost Project Cost Calculator ^ The total project cost very much resembles with the manufacturing cost graph and raw material graph which is obviously true as the cavity number affects those 3 values the same. However, positively sloped tooling cost curve in a long run forces the whole project cost to rise. It can be seen that for larger manufacturing volumes the flexion points of the curves shift to the right – the impact of rapid cost reduction due to increasing cavity number remains longer and this is because for small manufacturing volumes tooling costs puts a larger burden. Getting a quote - optimal injection molding price So in this case we had initial input values to start with (neglecting a lead time): Production quantity interval (e.g. 20k-50k pcs.) Project cost interval (e.g. 1000-5000 EUR) Molding cavities (e.g. 1-8) Optimal Project Cost at Various Production Volumes Opimal cost By using graph data and given input data, it is seen that optimal project cost can vary in region marked in red at various production quantities. However, it is also clear that project budget is underestimated by ~1000EUR by the client and the closest proposal to the given RFQ could be: 6000 EUR for 20000 pcs. with 4-8 cavities. The range of 4-8 cavities is used because there is no need to completely trust the data received. The project should be evaluated holistically and the very small win with a cavity number might not be worth it. Machining complex part tools or unforeseen problems while machining them might in reality become huge loss, thus some safety factor should be used. From the data above it can be seen that little does cost rise for more cavities at small production volumes. This is a perfect illustration of the power of injection molding in a mass production and economy of scale. Micromolding wins at small quantities From the discussion above it becomes clear that injection molding is for large manufacturing volumes only. Prototyping with injection molding becomes literally impossible. The main barrier to enter injection molding world is high tooling costs which disappear only when hundreads of thousands units are manufactured. What if it would be possible to save hugely on tooling and machine costs? Micromolding is a branch of conventional molding used for mass production of plastic parts. The main difference is that it is used to mold parts which are just fractions of a gram. However, micromolding technology can become useful when producing at low volumes or prototyping, since the molds used are small and made of aluminum. This reduces tooling costs and duration by 2x for small plastic part molding. Moreover, molding machines are small, thus operating costs are low too. In this way low-volume production and prototyping with injection molding becomes possible at low budgets. If the part is small enough to squeeze 4-8 cavities in the mold, competitiveness of micromolding at mass production scale matches the conventional molders. >>Read more about how micromolding enables 2x faster and 2x cheaper production<< Micromolding Back to top Read further Company Arginta visits Micromolds Arginta Group originates from the Lithuanian capital private limited company Arginta with the lifetime dating back to 1991. Promising... News Dominykas Turčinskas Dec 7, 2022 1 min read Laser & Engineering technologies cluster (LITEK) meets Micromolds Laser & Engineering technologies cluster LITEK was established in 2010 but cooperation between science and SMEs continues for more than... News Dominic Dec 7, 2022 1 min read Micro Milling Microfluidic Chips Creating microfluidic chips is a difficult and precise process. Manufacturers have several options available for creating small channels,... Blog Dominykas Turčinskas Dec 5, 2022 4 min read 1 2 3 4 5 Explore our services Smal 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 Micromolding begins when microfeatures take place and vary from 100µm to 5µm in size. Micro Injection Molding READ MORE Insert moulding is the process when components (e.g. wires) are encapsulated Insert Molding READ MORE Microfluidics, OEM solutions, clean room 8 molding, sterilization and medical grade plastics. Medical Injection Molding READ MORE

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