Search Results

Our short story ​ Micromolds℠ is part of a Lithuanian based Ltd. company "UAB Technoprojektai", founded in 2014 by our current CEO Jonas Tomkus who had previously been working as a senior mechanical engineer in the injection moulding field. His high expertise in engineering and passion to create, gathered like-minded engineers and formed a talented team. As a result, Technoprojektai has firmly established its name nationwide in micro moulding industry and thus has succesfully entered the global market. Did you see this wall of aluminum molds below? Piece by piece we brick this wall as we grow with our clientele. We are still halfway through but it already proves our proficiency. Jonas Tomkus , Founder of the company Our Environment ​ Micromolds℠ was selected as an innovative manufacturing spin-off company as a DIH (Digital Innovation Hub) member of Vilnius city. DIH is based in the building of Gamybos Inovacijų Slėnis (Manufacturing Innovation Valley) where all of the innovative manufacturing processes take place including Micromolding. 15 like-minded manufacturing companies from robotics to machining under one roof brings enormous value, resilience and capacity to us and this is the reason we are so proud of being DIH members. Our Network ​ Micromolds℠ is also a member of Inovatyvios Gamybos Klasteris (Cluster of Manufacturing Innovators).The cluster was established in 2020 with its main goal to unite companies of different sizes, the academic community, associations and other organizations into a club of leaders in manufacturing innovation. The cluster is a participant in the INOLINK project of the Agency for science innovation and technology. The cluster coordinator is UAB "Pažangios inovacijos". Our Ecosystem News about us Dec 7, 2022 1 min News Company Arginta visits Micromolds Dec 7, 2022 1 min News Laser & Engineering technologies cluster (LITEK) meets Micromolds Nov 24, 2022 1 min News Clusterisation in action Nov 11, 2022 0 min News Delegation from Finland Our scope ​ Mircromolds℠ divides its activities in main 4 activities: ​ Small parts molding Micromolding Medical injection molding Overmolding/insert molding Our values Honesty we declare the real lead times ​ Productivity we love engineering-like straight to the point communication ​ Social Responsibility we work with non-profit projects and firmly plan to continue doing so in the future ​ Growth we continuously invest time and capital to our team's expertise and personal development ​

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. 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 Twin 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 reproducibility of micro-molded parts Assembly tolerance fit compatibility Verify the intended design specifications ​ ​​ Contact an Engineer info@micromolds.eu Tel: +370 634 44885 ​ Nalšios g. 11, LT-14332, Vilnius

Microfluidic chip fabrication - micromolding lab on chip devices We are molding custom microfluidic systems twice cheaper and faster. ​ Get your micro-machined prototypes or large batch molded droplet microfluidic chips now! GET A QUOTE Enough working with PDMS chips ? Switch to plastics and scale up your production with micro injection molding technology SEE OUR PROJECTS Microfluidics Batch production Prototyping 1.Optimzing the Design Feature density Min. feature depth Aspect ratio Max. feature width Min. internal radius 2.Prototype or make a mold Precision milling Electro-forming Laser ablation Fused Silica Etching LIGA 3.Injection Molding Micro molding Vast material range Serial production Rapid prototyping 4. Sealing the Chip Hydrophobic Treatment Thermal Bonding Solvent-assisted bonding 5.Controling the Quality Functional testing Optical droplet manipulation analysis Testing critical features GET STARTED Micro molding Machines Low op. costs High throughput Easy handling Precision milling EDM machining Easy modification Aluminum micro molds Bundled Micro- inserts Change the inserts not the molds Bundle with other projects How can we cut the costs down twice ? By combining micromachines, micromolds, and micro-machining technologies we can offer an excellent balance between quality, speed and costs. Bundling micro inserts with other projects can reduce tooling costs twice . Prototype and test only the critical geometries We are enabling rapid prototyping with fused silica glass or micro milled chips by testing only critical features. Fused Silica Micro milling Test critical features Fluid manipulation and droplets of a desired size Molded​ microfluidic chips perform variety of tasks needed for biomedical engineering: ​ Droplet generation Splitting Merging Sorting ​ Microfluidic systems working principles are based on low-Reynolds number flow regime. Precise generation and repeatability of monodisperse droplets is the core of microfluidics technology and this is a single task we mostly focus to do. Applications of microfluidic cartridges Microfluidic devices serve for custom applications scattered throughout biomedicine and biotechnology fields. Continuous-flow based systems range from point-of-care devices and single cell microfluidic analysis (microfluidic cell culture) to organ on a chip devices. Even though not all droplet-based systems are disposable polymer microfluidic devices we focus on microfluidics fabrication from a single unit to a high volume production. Microfluidic droplet generators across the industries Microfluidics is a multidisciplinary technology which is used across variety of industries: ​ Chemical synthesis and biological analysis Advanced diagnostics and therapeutics Drug delivery Biomedicine and biotechnology Point of care diagnostics Organic synthesis ​ Whichever field of interest the project might be, we are always eager to contribute. ASK A QUESTION Our specialties Injection molding small parts READ MORE 'Micro' is not always 'micro'. If your part can fit in your hand - mold it 2x faster and cheaper with us. Micro injection molding Micro-injection molding begins when microstructures with a size of 100µm to 5µm are created. READ MORE With insert molding, components (e.g. wires) are overmoulded Overmoulding READ MORE Anchor 1 Contact an engineer info@micromolds.eu Tel: +370 634 44885 Nalšios g. 11, LT-14332, Vilnius

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 – analysis of its features as well as materials used with it, packaging challenges, design for manufacturability and the future horizons of micro molding. Table of Contents: ​ What is plastic micro molding and its features? Could micro injection molding replace conventional injection molding? How extensively µIM is used across industries? Micro molding in medicine Micro molding in electronics Micro molding in automotive H ow far could thin wall molding go? What materials are the best for micromolding? What are the future of micro injection molding technology? Challenges in micromolding: micro assembly and packaging Anchor 1 What is plastic micro molding and what are its features? ​ Micro molding is a highly specialized process where micro-structured steel or aluminum molds are CNC and EDM machined within micron or even submicron scale tolerances. Usually, when molded part weighs fraction of a gram or its micro features range from 50µm to 5µm or less in largest side micro molding world reveals. ​ The main difference between micro molding and traditional molding technologies is the shot size and the precision of injection machines. Micromolding machines can inject fraction of a gram with high precision as they have higher resolution feed options which results in even pressure distribution inside the cavity. In micro injection molding smaller molds are used too. Micro molds are machined with smaller cores and cavities and micro features inside with precision CNC and EDM tools. In conventional molding things like packaging and quality management can be viewed as secondary operations, however, micro molding process demands extensive attention to packaging and quality control details, since molded parts are very small. ​ Could micro injection molding replace conventional injection molding? ​ The answer is: YES. Micromolding sometimes can be ‘small’ but not ‘micro’. In a vast variety of demanded plastic parts many of them might be small enough to fit in micro mold projected area (e. g. of ⌀~100mm circle perimeter) and not to exceed micro injection shot volume (e. g. ~15-30cm3). Moreover, innovating companies often seek for resilience and low-risk market entrance with pilot launches with manufacturing volumes up to 100k pcs. Anchor 2 In these conditions there will be no better way than using micromolding technology. A significant cost and time reduction is possible compared to traditional injection molding. It is possible to save up to 3-4x on tooling costs and enter the market with finished products in less than 3 weeks: ​ Low machine operating expenses, since there are smaller machines used and lower clamping force is exerted. Fewer mold cavities and aluminum used results in faster and cheaper machining. Waste minimization due to shorter runner systems required. Since there are shorter runners needed to fill in the cavities, there is a dramatic difference in the volumes of cut and disposed runners, in comparison to traditional injection molding. Easy and flexible modification is possible due to the fast and low cost mold machining. How extensively µIM is used across industries? Medical and Healthcare industries ​ Undoubtedly, the field of medicine as such requires an extreme accuracy in most of the processes. Therefore, in many cases, the medical instruments used must be small and highly sophisticated. Thus, micro molding is widely used in medical devices manufacturing: drug delivery devices, catheters, diagnostic systems, optical and hearing aid components, etc. and is highly applicable for the instruments of minimally invasive surgeries. For instance, neurosurgeries, aortic treatments, etc. It might also be stressed that new types of microfluidic systems are becoming more and more popular and widely applicable in various medical performances (including Point-Of-Care applications). No surprise that medical industries capture approximately a quarter of the global market share of micro injection molding, according to 'Mordor Intelligence' Anchor 3 Anchor 4 Electronic industries ​ Since modern electronic devices are getting smaller, there is a growing need of high precision and complexity for this sector, too. Micro molding benefits may be exploited in various electronics components manufacturing. Micro-optics might be one of some examples (e.g., manufacturing laser-based devices, smart phones, lenses, prisms, etc.). As well as microelectronic components: such as connectors, switches, plugs, computer chips, etc. for computers, communication technologies, musical devices and other microelectronics fields. ​ Microelectromechanical systems (MEMS) often require micro molding manufacturing, too. Since the industry itself is in the growth stage, the demand for innovative micro molding in manufacturing processes is increasing as well. For instance, BioMEMS (Biomedical Micro-Electro-Mechanical Systems) are now being widely investigated and potential Next Generation Sequencing (NGS) and Point-of-Care diagnosing opportunities already applied which significantly increases the demand for MEMS. ​ The rapid development of modern technologies leads to a dramatic growth in electronic industries and this might be represented by the fact that electronic sector holds a little bit more than a fifth of the global micro injection molding market share (ibid). Anchor 5 Automotive industries ​ Micro injection molding is quite widely used for manufacturing automobiles’ components which frequently require light and small components. Micro molding is used for under the hood parts (e.g., engine or breaks) of a car and for various other components relevant for automotive industry, such as different clips, washers, door locking mechanism parts, various buttons, switches and even for micro plastic gear manufacturing. Since the whole automotive industry is huge and requires many micro parts, no wonder why this sector captures the most value (almost a third) from micro molding (ibid). Anchor 6 How far could thin wall molding go? ​ Firstly, to discuss thin wall molding, the concept itself should be clarified. Thin wall molding can be classified according the ratio of flow length and wall thickness: L/t ratio. As different plastics have different flow rates their maximums of the ratios will vary accordingly. Here are the maximums of L/t ratios for 10 of the most widely used thermoplastics: ​ ABS: 170/1 SAN: 120/1 PA: 150/1 PC: 100/1 HDPE: 225/1 LDPE: 275/1 PP: 250/1 PMMA: 130/1 POM: 150/1 PS: 200/1 ​ The quality of the molded part is highly dependent on correct design of wall thickness. By highlighting ‘correct’ design it is meant to choose compatible ranges of wall thickness for various thermoplastics and to maintain similar aspect ratios throughout whole part design process. Failing in this design for manufacturability stage may lead to: ​ Timely cycles, since thicker walls cool longer than the thin ones; Too thin a wall might be too fragile and in addition, may cause flow rate (the speed of flowing into cavities) errors. The latter issue may result in voids if material does not fill all the features before it cools; Uneven walls cool and solidify differently, and this factor is usually a reason why there might exist any unintended permanent warps or sink marks on the molded part surfaces. ​ Since thin wall molding is primarily dependent on resins choice it is good to refer on some experimental data. The table below demonstrates the most widely used plastic materials with minimum and maximum wall ranges for injection molding: Anchor 7 MATERIAL ​ ABS ACETAL ACRYLIC NYLON (POLYAMIDE) POLYCARBONATE POLYESTER POLYETHYLENE POLYPROPYLENE POLYSTYRENE POLYURETHANE APPLICATION ​ Mostly for plumbing or automotive industry May replace some parts that used to be metallic Mostly replacing glass for beauty, fashion or even art industries Various industrial and mechanical uses Used in a wide range of markets Used in a wide range of markets Perfect for disposable and recyclable products Various application possibilities, however, frequently used in food industries, since it does not leach chemicals Applicable in various industries Applicable in various industries WALL THICKNESS ​ 0.143 mm – 3.556 mm 0.762 mm – 3.048 mm 0.635 mm – 12.70 mm ​ 0.762 mm – 2.921 mm 1.016 mm – 3.810 mm 0.635 mm – 3.175 mm 0.762 mm – 5.080 mm 0.635 mm – 3.810 mm ​ ​ 0.889 mm – 3.810 mm 2.032 mm – 19.05 mm When resin material is chosen some other requirements must be met for thin wall molding. Since thin walls cool faster than thick walls, thin wall molding requires the higher speed of cavity-filling (fill time indicates the time required for the material to flow into cavities). For instance, a 25% drop in wall thickness needs a 50% drop in time of injection. Thin wall manufacturing requires specialized machinery to process higher speed and pressure. Even though modern technologies allow standard machinery to fill thinner and thinner parts, the tiniest parts require more advanced machines for both, injection and clamping, cycles. Anchor 8 What materials are the best for micro injection molding? ​ There is a high variety of materials that may be used in micro molding. However, there definitely are some crucial constraints not to forget while choosing materials, such as: mechanical properties (what are expected operating environment, high-heat situations, hygroscopic properties?) compatibility (contact with other biological bodies, cosmetic appearance and price. Some of the most popular materials for micro molding are shown in the table below. ​ MATERIAL ​ LCP (liquid crystal polymer) PMMA (polymethylmethacrylate) COCs (cyclic olefin copolymers) PEEK (polyether ether ketone) PLA (polylactic acid) PGA (polyglycolic acid) ​ Polyethylene Polypropylene Polycarbonate APPLICATION High temperature tolerance; Great chemical and weathering resistance; Stress cracking resistance Great transparency; Ultraviolet radiation resistance; Scratching resistance Great flowability; Heat, chemical, moisture resistance; High clarity High chemical resistance; Great heat and pressure tolerance; Stress-crack resistance and high strength Biodegradability; High transparency; Great compatibility Biodegradability; High strength; High abrasion and solvent resistance ​ Great chemical resistance; High strength and surface hardness; Abrasion resistance Great chemical and heat resistance; High flexural strength and fatigue resistance; Electrical insulation High transparency and high dimensional stability; Rigidity and toughness; Moisture and chemical resistance Anchor 9 It should also be highlighted that with the rapid technological development and the growth of demand, there is an increase in the use of bioabsorbable polymers in micro injection molding. Bioabsorbable materials are widely applicable in modern healthcare. Since these polymers may be absorbed and dissolved by a human organism, the use of them lowers the number of surgical interventions needed for specific (most usually, orthopedic) treatments. Along with the innovations, grows the demand for the applications of these materials and this is where modern micro molding technologies are used, too. What is the future of micro injection molding technology? Plastic injection molding is used in a majority of industries across the world. Old manufacturing technologies are replaced or upgraded by the new ones and the industry 4.0 is catalysing all of it. Micromolding is not an exception and thus must to remain innovative and to adapt to the new market demands where components are getting smaller and smaller. For this reason, new technologies are being developed to improve micromolding: ​ Significant progress in substance control. The most visible progress is that companies are trying to research the recycling of polymers and this research is associated with environmental considerations; New innovations depend on customer needs, it’s because sometimes they require something that companies cannot create. This demand puts a lot of pressure on manufacturer and for this reason new technologies are being produced, for example, extreme thin wall molding, 2-shot micro molding and automatic insert molding, are direct results of the market demands; New micro molding sensors have been specially adapted to the mould, previously the sensors were too large. New sensors are very compact, easily installed, save significant space in the mold and are designed to monitor temperature, pressure, warpage, shrinkage and others processes; One of the latest innovations are CNC machine tools and micro sinker EDM. These devices allow molders to inject shots of less than 1 gram with minimal damage and very high shot accuracy. Advances in shrinking pressure and temperature sensors hardware allow for better control and real-time monitoring of the process. ​ ​Runnerless or reduced flow path molds are designed to save expensive materials and it will allow machine manufacturers redesign to achieve high accuracy and ultra-small shot sizes. New advances include non-standard material designs, improved reduced wall thickness filling options, stress removal and mold annealing, improved mold and material monitoring systems. Challenges in micromolding: micro assembly and packaging ​ Packaging and micro assembly cost is a big portion of the overall cost of any micro-scaled product and it is an important part of the development of a microscopic product. Efficient packaging and assembly is a key for success products in the marketplace. ​ Anchor 10 The main reason for the cost of packaging and assembly of micro-scaled products is the lack of automation in both of these operations. Most micro-assembly requires the use of operators to manually select and insert small parts using powerful microscopes and micro-tweezers. Manual assembly is extremely expensive and takes a lot of time. Operators who are assembling such a micro-scaled parts, suffer from the tension on the eye strain, have strict requirements for the final product, but must also achieve the required reliability of its quality. ​ To make micro-assembly easier and much quicker, several specific tools and equipment must be available for this process: ​ Visual system with high-performance stereo microscope, long-lasting distance and high resolution camera and monitor. The latter is used to provide instructions and feedback during and after assembly; Micro-positioner with a resolution of 40 nm for workpiece control, microgripper and position management; Real-time computer vision for controlling servo mechanisms and motors and assemble parts within micron level accuracy; ​ ​ High resolution, high precision transfer tool for handling parts and components. ​ If you are making a micro-scaled product and you don’t want to assemble it under the microscope, there are some methods that helps to combine different parts together at the design stage: ​ Two-shot micro molding. This method let to inject two different materials into a mold at two different or in the same place. Ultrasonic welding. It is affective when joining thermoplastics and compatible metals; Laser welding. This is usually used for joining micro components, when 3D geometry cannot be combined through overmolding. Laser welding also can be used to clean and disassemble materials such as wires quickly and without breaking them; Staking. This is a very cheap way for assemble polymer and metal by using folding of one material into another; Solvent bonding is known as cheaper and faster way for joining micro-scaled components. Typically, it is combining different materials and solvents, using micro and nano pipettes. Those two components, must be bonded together, especially if this combination will be used as an implant. ​ Packaging of micro components is as important as micro-assembly. Each micro-scaled part must be delivered to the customer safely. When sending small, sharp or friction and vibration sensitive parts, packaging can be a very difficult process, it has to be well thought out. Micro-packaging requires components to be individually packed in special packages or pallets. When dealing with clean room requirements or ISO 13485 quality assurance it is also very important to ensure an appropriate temperature of machines and airflow around it. Usually it is a must to have fans generating filtered airstreams to prevent air contamination and dust attaching to the molded parts until they are packed. Back to Top Table of Contents: ​ What is plastic micro molding and its features? Could micro injection molding replace conventional injection molding? How extensively µIM is used across industries? Micro molding in medicine Micro molding in electronics Micro molding in automotive H ow far could thin wall molding go? What materials are the best for micromolding? What are the future of micro injection molding technology? Challenges in micromolding: micro assembly and packaging 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 Read more: Dominykas Turčinskas Dec 7, 2022 1 min News Company Arginta visits Micromolds Arginta Group originates from the Lithuanian capital private limited company Arginta with the lifetime dating back to 1991. Promising... 50 0 Dominic Dec 7, 2022 1 min News 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... 26 0 Dominykas Turčinskas Dec 5, 2022 4 min Blog Micro Milling Microfluidic Chips Creating microfluidic chips is a difficult and precise process. Manufacturers have several options available for creating small channels,... 72 0 1 2 3 4 5

Thank You! Your information has been successfully received. KNOW US BETTER

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

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 ​ Dominykas Turčinskas Dec 7, 2022 1 min News Company Arginta visits Micromolds Arginta Group originates from the Lithuanian capital private limited company Arginta with the lifetime dating back to 1991. Promising... 50 0 Dominic Dec 7, 2022 1 min News 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... 26 0 Dominykas Turčinskas Dec 5, 2022 4 min Blog Micro Milling Microfluidic Chips Creating microfluidic chips is a difficult and precise process. Manufacturers have several options available for creating small channels,... 72 0 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

Injection Mold Making: Types of Molds Mold is a piece of block used in the injection molding process to mold various plastic components. It might be the most expensive component used along with the injection molding machine due to its complex design, precise characteristics, and manufacturing methods. In other words, mold is a hollow metal block where the molten plastic gets injected to manufacture the desired shape. Usually, tooling is done by CNC machines. Molds are fastened to the platens of the injection molding machine. They have drilled holes and channels responsible for controlling the temperature of the mold by circulating hot water. As far as the mold's working is concerned, molten material flows into molds through a sprue and fills the cavities. After a calculated time, the molten material adopts the shape of the mold and solidifies. Then the injection molding machine pushes the ejector plate of the mold to repeat the process for further manufacturing. Table of Contents: ​ Types of Molds used in Plastic Injection Molding Advantages of Aluminum Molds Disadvantages of Aluminum Molds Advantages of Steel Molds Disadvantages of Steel Molds The Process of Mold Making Things to consider about Mold Making Conclusion Anchor 1 Types of Molds Used in Plastic Injection Molding ​ Mold materials must be wear-resistant and withstand many cycles, the clamping force required to hold the material set up, and the high-pressure forces to shape the liquid plastic and achieve close tolerances. While considering the materials, molds can get divided into two categories: aluminum molds and steel molds. Molds made up of these materials have their specified applications. ​ Aluminum Molds Aluminum has been on the cards for mold manufacturing for the last few years. While being less expensive solutions of P20-tools, automotive industries are shifting molds to aluminum. Usually, aluminum molds manufacture low-volume tools or prototypes since molds are malleable and softer than conventional steel material. Consequently, wear and tear are more pronounced, and continuous use might cause marks on the manufactured product. Steel Molds Steel molds have been a conventional approach in the field of injection molding. Nonetheless, molds made up of steel are highly suitable for high-volume production because steel has a more remarkable ability to withstand internal and external stresses and remains invincible against wear and tear for a longer run. Additionally, the steel molds are highly durable with expanded options of use even after maintenance, though they cost heavily compared to aluminum molds. Anchor 2 Advantages of Aluminum Molds Here are some of the most substantial advantages of aluminum: 1. Lower Tooling Cost If compared to the molds of steel, the tooling cost for aluminum molds is much lower. Some aluminum tooling is as more economical as half of the cost of steel tooling. Although the return on investment for steel mold and aluminum mold may vary greatly depending upon their use, aluminum mold requires a meager initial investment compared to steel. 2. Reduced Heating and Cooling Times Aluminum has much higher dissipation rates than steel, so aluminum can instantly turn hot to cool and vice versa. Thus, the cycle time of aluminum mold is 20-30% better than steel molds. Keep in mind that an improved heat dissipation rate is not only appropriate to abstain from cooling and heating lines, but it also diminishes the intricacy of mold and maintenance costs. 3. Ease of Modification Aluminum is suitable for low-volume production since it is relatively softer than steel and gets worn sooner than steel. However, the quality of being soft allows engineers and manufacturers to modify and optimize the design according to advanced needs. Disadvantages of Aluminum Molds Aluminum has some disadvantages too that might cause its replacement with steels molds: 1. Less Compatibility with Materials Unlike steel molds, aluminum has compatibility issues with complex injection molding resins. For example, polymers with fiberglass cannot be used with aluminum molds even for a very few cycles. Moreover, aluminum molds are softer and gentler and more inclined to scratches/damages brought about by some special resins. 2. Low-Volume Production Runs Manufacturers must keep in mind that they cannot depend on aluminum molds for high-volume production runs due to their ability to be more delicate than steel molds. Otherwise, the quality of the eventual product gets badly affected and damaged. Anchor 3 Anchor 4 Advantages of Steel Molds Steel has been the focus of injection molding owners for a long time. Here are its reasons: 1. Perfect for Detailed Features The prominent feature of steel is its ability to be suitable for high-volume production because of its resistance against wear and tear and higher hardness and strength. At the same time, this is the reason that helps manufacturers achieve detailed features of mold. For example, steel molds tightly follow thin, non-uniform walls and rounded angles to bring a better shape to the final product. 2. Improved Durability Though steel is more expensive than aluminum, steel molds offer more comprehensive and durable services than aluminum. In addition, steel with a better ability to sustain stresses does not fall for repairing or early retirement. Also, steel is ideal for long production runs and frequent utilization of the mold throughout the long term. 3. Higher Compatibility Steel molds are highly suitable for complex and advanced injection molding resins since steel can stick to even hard-featured products, which is usually challenging with the aluminum product. Likewise, steel molds are compatible with resins reinforced with additives such as glass fiber. Disadvantages of Steel Molds Apart from its advantages, here are some of the disadvantages of steel molds: 1. Higher Tooling and Repairing Cost Steel is highly reliable and durable, but it possesses excelling costs that are not justified compared to aluminum or its other counterparts. Given that, for making the steel mold ready, there needs a higher tooling investment. Equally, steel molds, if fall for warping or some other defects, the repairing costs are higher due to their increased hardness. 2. High-Volume Production Runs Since steel molds are expansive in tooling and repair, they will be suitable and economical only for high-volume production runs. On the other hand, as mentioned earlier, aluminum molds are preferable for low-volume production runs. ​ The Process of Mold Making The mold manufacturing for injection molding is a multi-staged process. Throughout the process, it is inevitable to consider the required dimensions of the final product. Plus, risk management to avoid mold failure and ensure its accuracy, tightness, and ventilation is also necessary. Anchor 5 Anchor 6 Anchor 7 Things to Consider about Mold Making Mold manufacturing entails accuracy and techniques and may involve block molds, glove molds, blanket molds, poured molds, and then some. The time may differ with various strategies regarding creating easy to complex geometry. The types of molds, like single or multiple cavities, can be picked as per requirements. Additionally, ensure access to adequate materials, provisions, and tools & equipment. Diverse material alternatives, such as aluminum and steel, are available, and each has specific features, capacities, and suitability. Nevertheless, the budget of the project is also one of the key things to consider, since mold making cost highly affects the final cost of injection molding . Primary Operations like Milling and Turning Typically, the drawing of the final product gets prepared before mold manufacturing. This design of the final product further leads to mold making. Metal blocks of required sizes are taken and aligned on a CNC machine. Before starting the secondary operations, CNC performs primary functions like milling, turning, and heat-treating on the metal block. During the mold making process, a selection of cutting tools gets made considering the material of molds. For steel, carbide tools get widely used because they are among the hardest cutting tools. Secondary Operations like Mold Construction and Peripheral After completing the primary operations, the metal block is all ready to go under the secondary process, which ensures the mold-making process's success. These operations may include mold construction and mold peripheral. Mold construction provides closing and clamping of molds, mold wall thickness and centering for proper heat absorption and dissipation, and mold surfaces through grinding, polishing, sandblasting, or shot peening. Besides, mold peripheral comprises ensuring mold venting, non-permanent release agents to get applied to the mold surface for improved demolding properties, permanent release coatings for better flow properties and gradient blend, and threaded inserts such as snap inserts or magnetic holders. ​ Conclusion Injection mold making is a highly technical and skill-required task, such as process control and troubleshooting of quality defects. It needs to eliminate loopholes that may cause potential losses throughout the process. For now, the molds are revolving around two materials: steel and aluminum. Molds made up of these materials have their specified advantages and disadvantages along with their specific costs. And choosing the mold material depends on many factors, such as the cost-efficiency and product specifications to be achieved. ​ But remember, even though the innovation has been around for a long time, the field of injection mold making keeps on developing, considering new technological improvements, market disruptions, and different social and economic aspects. Accordingly, the five key industry trends that shape the heading of injection mold manufacturing include moving towards sustainability, exploring various substitute materials, automation, machine learning, and advanced analytics. Anchor 8 Back to Top Table of Contents: ​ Types of Molds used in Plastic Injection Molding Advantages of Aluminum Molds Disadvantages of Aluminum Molds Advantages of Steel Molds Disadvantages of Steel Molds The Process of Mold Making Things to consider about Mold Making Conclusion 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

Rapid Injection Molding ​ Sub-contracting micromolding company may be very beneficial for companies which are creators and innovators capturing every oppurtunity occuring in the market. Supply chain and manufacturing processes must be very fast and responsive when custom-made products are needed. Not to mention high competition emerging from smaller startup companies which can be faster and more flexible when adapting to the market conditions. Shorter and shorter product life cycles where rapid prototyping is key in saturated markets plays a major role too. To remain resilient and responsive companies sub-contract firms like ours - digital manufacturers - who are able to lessen the risks occurring from changes in the market by rapidly supplying missing manufactured product components. ​ Speed is everything in today's manufacturing world. And this is what we can do. Thanks to digitization we are able to reduce time to market by 2 times. We eliminate worthless and time-consuming email communication to get quotations. It can take weeks to agree on terms and design requirements, especially when dealing with several potential contractors. Digital manufacturing is all about speed - sent CAD drawings can be automatically evaluated by intelligent software: recommendations and optimization for manufacturability are sent back in hours with preliminary cost of tooling estimations. Later on same CAD optimized drawings can be sent straight to CNC machines and production starts almost without human intervention.

Mould tool design - aluminium moulds We are mold manufacturers ​ We are not some chinese mold makers - we make high quality aluminium micro moulds locally from product idea to CNC milling and surface finishing. Aluminum injection moulds are faster and cheaper to machine 20-40% than steel moulds respectively and can sufficiently pass ~100 000 cycles. As a molding supplier we also take into account your branding opportunities and offer in-mould labeling and wide range of surface finish options. ​ Moulding tool design requires expert-level mechanical engineering knowledge which "Micromolds" team rest assured have and is ready to help on your next projects. Whether you are in an idea stage or have you part's primary design we will assist you through whole injection mold design process or will design moulding die in a CAD format ready for machining. Rapid tooling (Aluminum + 3D printed) ​ Rapid tool and mould design can be achieved when whole contract manufacturing process is highly efficient. It means that on every stage while making an order valuable customer's time is used at its most and errors are foreseen as early as possible. Starting with online fast-line quoting process and ending with aluminum moulds shipping we believe that we have refined the whole process and can deliver projects in less than 2 weeks. ​ Duration of making injection moulding die is one of the main considerations when talking about rapid tooling. Thus we have chosen aluminum moulds which can be machined significantly faster than steel dies. Also, we offer SLA (Stereolithography) 3D printed moulds with aluminum fixtures. Aluminum cases adapt and enable SLA printed moulds to work with our injection machines. Micro moulds ​ 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 . ​ ​ Part design ​ Before making injection molds plastic part design is crucial. We have wide experience in working with not only injection moulding projects and thus we are confident that we can help out to make your idea reality. Even if you have your 3D part design we will perform DFM and mouldability analysis to optimize topology and shape of your part for efficient injection moulding production. What's more ​ We understand that on demand manufacturing requires as much resilience as speed in todays fast moving industries. Thus we offer trouble-free injection mould modifications. Also, if you are looking moulds for sale we offer e xport injection mould and can ship worldwide. We freely agree that customer owns the mould if demanded so and we provide it with l ifetime warranty. Rapid tooling Micro moulds Part design Make your mould now! 1 2 3 4 To start just upload CAD file of your part In few hours DFM and prcing is performed Once an order is placed manufacturing begins Parts are shipped in 1-2 weeks GET STARTED Read about us more '' 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. ''

Cable overmolding and insert molding Low pressure elastomer and thermoplastic overmolding across variety of industries in record fast lead times GET A QUOTE Overmoulding The projects that could be yours Explore our recent overmolding projects across the industries and see a backstage of true insert molding technology A smartwatch that revolutionizes health monitoring READ MORE 1.Upload CAD No registration .step file Few seconds 2.Get Quote Real engineer guidance Transparent pricing 1 hour 3.Optimization Design assistance Exceptional attention Free of charge 4.Manufacture Tooling + molding Resilient schedule 2 weeks 5.Get Parts Packaging + assembly Shipping 1 day GET STARTED Low operating costs Easy handling Small Machine Small Molds Fast tooling Easy modification Cheaper tooling Easy machining Aluminum + 3D print molds How can we do this? By using small machine and small aluminum molds we can offer outstanding quality to flexibility, speed and cost ratio. ​ ​ "An average project cost range up to 2500 EUR" READ MORE Win at low-volume production We are bridging prototyping and mass production phases and standing between 3D printing and traditional molding. READ MORE Cable overmolding Specifications (For those who love to read) Overmoulding ​ Two molds are typically used in overmolding. One is for the primary part layer - the substrate part and the second is for the second part to overlay the substrate. Overmolding allows plastics of different colors or physical properties to fuse together. For example, a clear acrylic lens can be overmolded into a PCB plastic housing. So overmoulding is very similar to 2-shot process but requires more manpower and two molds but cheaper with less production. 2K moulding (double shot moulding) ​ Multi shot overmoulding is used when several resin components have to be meld together. In this way workpiece can be moulded multi colored and with required distinct physical properties, e. g. part can consist of polymer injected hard cover and elastomer injected soft cover sections. Component resins are strongly bonded chemically and thus final product is durable and wear resistant. Main distinction between Overmoulding and 2 shot moulding is that 2K is performed with more expensive and complex machining and thus is usually more expensive and breaks even at larger production volumes. 2K moulding Wire overmolding Insert Moulding ​ Insert moulding is the process when usually electronics' components e. g. cables or circuit boards are encapsulated. Low pressure moulding (LPM) is used in such cases. Wires or PCBs are covered by layers of polymers to protect them from mechanical fatigue or environmental effects respectively. As the name of LPM itself suggests low pressure allows low-viscosity materials, e. g. hot melt polyamide materials, to easily flow in room-temperature moulds with inserts in it. When solidified, insert together with overmoulded material are ejected from the cavity manually or automatically and the process is finished. ASK A QUESTION Our specialties Injection molding of small parts '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 Contact an engineer info@micromolds.eu Tel: +370 634 44885 Nalšios g. 11, LT-14332, Vilnius

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