Microfluidics manufacturing at scale demands more than a good prototype. The path from a validated PDMS chip to a reproducible, production-ready custom microfluidic device is where most R&D programs stall and microfluidic injection molding is how the best teams cross that gap. The Reproducibility Wall Every Researcher Hits Microfluidics manufacturing is a discipline with a reproducibility problem and it starts long before production. You've validated the assay. The droplet generation is consistent, in your hands, on your bench, with your protocols. The paper is written. Then someone asks: "Can we scale this? Can another lab reproduce it?" That's the moment most microfluidic R&D programs discover they've been building on sand. PDMS (polydimethylsiloxane) is a brilliant material for rapid prototyping. It's oxygen-plasma bondable, optically transparent, gas-permeable, and you can cast a new chip in an afternoon. But it is not a manufacturing material. It is a research material. The hidden cost of PDMS at scale: Channel dimensions vary by ±15–20% batch-to-batch depending on curing temperature, mixing ratio, and bake time. Surface chemistry changes over hours after plasma treatment. Small molecules, drugs, dyes, signaling lipids, absorb into the bulk at rates that vary with batch. For quantitative assays, this isn't a minor inconvenience; it's a systematic error source. The transition from PDMS prototyping to thermoplastic injection molding is therefore not a manufacturing upgrade, it's a scientific one. It's the point at which your device stops being a handmade instrument and becomes a reproducible, characterizable substrate. It's when your microfluidic research becomes microfluidic technology. This article is for R&D engineers who are ready, or nearly ready, to make that transition. We'll cover the engineering rationale, the material science, the process architecture, and the practical steps to commissioning custom microfluidics manufacturing through injection molding. Why Injection Molding Is Ideal for Custom Microfluidic Chips Injection molding is the dominant manufacturing process for polymer precision components for a simple reason: it enforces geometric repeatability through physics, not operator skill. Once a mold is qualified, every cycle reproduces the same cavity geometry, the same channel cross-sections, the same surface roughness, the same feature depths, within validated tolerances. For microfluidics manufacturing, this matters at a fundamental level. Pressure drop in a rectangular microchannel scales as the fourth power of hydraulic diameter (Hagen–Poiseuille regime). Even small variations in channel dimensions can lead to significant changes in fluidic performance.In PDMS, that variation is routine. In a precision-molded thermoplastic chip, the product of microfluidic injection molding, it's controlled. And when you're working with feature dimensions in the 10–500 µm range. At these dimensions, process control becomes critical for achieving reliable and repeatable assay performance. 50–500 µm Typical channel dimension range in precision injection-molded microfluidic chips Shot-to-shot consistency as a scientific asset When you run an experiment with injection-molded chips, you're not fighting your substrate. Every chip in the lot is manufactured to the same validated geometry and process parameters. That means your N is really N — not N chips with hidden chip-to-chip variance baked in. Statistical power goes up. Outlier investigation becomes meaningful. Platform studies across sites become feasible. Scalability without redesign Perhaps the most strategically valuable aspect of custom microfluidics manufacturing via injection molding is that the same manufacturing platform can support both prototyping and volume production, minimizing the need for process changes during scale-up.The tooling that validates your design at prototype scale is the tooling, or a direct extension of it, that runs your production lot. There are no new bonding chemistries to validate, no new surface treatments to qualify, no batch-to-batch material variation to characterize. The design is fixed in steel and aluminum. This is not possible with any soft-lithography approach at scale. For an engineering comparison of replication processes, see hot embossing vs. micro injection molding for microfluidic devices. PDMS soft lithography Thermoplastic injection molding Fast initial prototype (<24 hrs) Low setup cost Batch-to-batch dimensional variance ±15–20% Small molecule absorption artifacts Not autoclavable Manual assembly required Not scalable beyond ~hundreds of units Prototype tooling in 1–3 weeks Dimensional CV <1% across lots Chemical resistance (material-dependent) No molecular absorption (COC/COP) Autoclavable (PC, certain grades) Scalable to millions of units Optically clear for imaging Material Selection for Custom Microfluidic Chips The choice of thermoplastic is not a commodity decision in microfluidics. It determines optical transmission, autofluorescence background, surface chemistry, chemical compatibility, and the minimum feature size achievable under production conditions. Here's what matters for each major candidate: Material UV Transmission Autofluorescence Chemical Resistance Best For COC (cyclic olefin copolymer) Excellent (>300 nm) Very low Good (most aqueous, some organic) Fluorescence assays, diagnostics COP (cyclic olefin polymer) Excellent (>300 nm) Very low Good (similar to COC) Cell culture, optical detection PMMA (acrylic) Good (>350 nm) Low–moderate Moderate (avoid strong solvents) Cost-sensitive, high-clarity applications PC (polycarbonate) Moderate Moderate Moderate–low Structural components, thermal stability PS (polystyrene) Good (visible) Moderate Moderate Cell biology (established protocols) Engineering note on COC/COP: Both cyclic olefin materials have near-zero water absorption (<0.01%), making them exceptional for assays sensitive to hydration state. They also lack the ester groups that cause PMMA to hydrolyze under aggressive sterilization conditions. For IVD and clinical applications, COC/COP are often the path of least resistance through biocompatibility qualification, both have established USP Class VI and ISO 10993 data packages. The molding constraint on material choice Cyclic olefin polymers have high melt viscosities and relatively high glass transition temperatures (Tg typically 70–170°C depending on grade). This means filling micro-scale features requires careful thermal management of both mold and melt, a capability that separates specialty microfluidic molders from general-purpose injection molders. Processing (dynamic mold temperature cycling) is often essential for feature depths below 50 µm in high-Tg grades. Custom Microfluidic Chip Manufacturing at Micromolds Custom microfluidics manufacturing via injection molding is not a single step, it's a stack of tightly coupled engineering disciplines that must remain aligned from the first CAD commit to the final inspection report. Here's how Micromolds structures that stack: Design for Manufacturability (DfM) Review Before tooling is cut, the microfluidic architecture undergoes a Design for Manufacturability (DfM) review to assess microfluidic injection molding constraints: draft angles, wall thickness gradients, gate placement, and weld-line positioning relative to critical flow features. Designs Mold Tooling — Prototype or Bridge Prototype tooling (1–3 week lead time) enables functional validation under production-like conditions before committing to hardened production steel. Space-grade aluminum alloys with fine crystalline microstructure (±2 µm) allow feature replication that rivals steel tools, at a fraction of the cost and time. Bridge tooling enables low-volume pre-production runs while the final production tool is being qualified. Micro Injection Molding Microfluidics injection molding help ensure complete replication of fine microfluidic features by minimizing polymer melt hesitation during filling. Critical process parameters, including injection speed, packing pressure, mold temperature profile, and cooling time, are tightly controlled and documented for every production lot. Typical channel dimensions range from 100–500 µm in standard production, while sub-100 µm channels and features can be achieved in selected applications following design review and feasibility assessment. Bonding & Sealing Microfluidics bonding process selection depends on channel geometry, pressure requirements, and whether optical access through the bond plane is required. Each method has tradeoffs in minimum channel dimension preservation and burst pressure. Metrology & Quality Control Dimensional verification uses optical profilometry and confocal microscopy. When measurement system variation approaches part variation, a common challenge at the micro scale, Gage R&R studies are essential to distinguish process drift from measurement noise. 100% in-house capability means no tolerance on inspection lag. Cleanroom Packaging & Delivery Production microfluidic components are handled, inspected, and packaged in controlled environments. Contamination at the chip level, particulates in sub-200 µm channels, can invalidate entire production lots. In-house cleanroom capability eliminates transfer risk. Tolerances, Features & What's Actually Achievable Claims about achievable feature sizes in micro injection molding are common. What's less common is a frank account of the conditions required to hit them reliably, at production volume, in the materials that matter for microfluidics. Production capability benchmarks — Micromolds Parameter Performance Minimum channel width 50–100 µm (down to 10–20 µm for selected applications) Minimum channel depth 20–50 µm (down to 5–10 µm) Dimensional CV (width, lot-to-lot) Typically within ±5–10 µm, depending on geometry and material Channel aspect ratio (depth:width) Up to 1:5 Surface roughness Ra ~50 nm depending on mold insert finish Parts per cavity per cycle 1–2 (micro cavities) Prototype tooling lead time 1–3 weeks Production tooling lead time 6–8 weeks Production volumes From prototyping to mass production One underappreciated constraint: mold surface finish directly determines channel wall roughness, which affects both optical clarity and the stability of electroosmotic flow (EOF) if you're running electrophoretic separations. Electropolishing of mold inserts, combined with traditional optical polishing, can achieve channel walls with Ra <10 nm, sufficient for single-molecule imaging applications and low-noise impedance spectroscopy. For simulation-driven projects: Micromolds collaborates with specialized microfluidics partners for complex computational fluid dynamics (CFD) validation and multi-physics simulation of device behavior under production geometry constraints, not just the idealized CAD model. Transitioning from PDMS: A Practical Roadmap The most common question from R&D teams approaching custom microfluidics manufacturing for the first time: "Can we just translate our PDMS design directly into plastic?" The honest answer is: sometimes yes, often not without modifications and the modifications are almost always worth making. What transfers well Channel topology, valve geometry (if translated to a rigid-body design), junction architecture, and overall chip footprint all transfer straightforwardly. If your PDMS chip is running a well-understood flow regime, pressure-driven laminar flow, simple droplet generation, passive mixing, the physics transfers cleanly into a thermoplastic equivalent once channel dimensions are adjusted for any shrinkage or material-specific flow resistance differences. What requires redesign PDMS chips rely on the material's elasticity for certain valve types (Quake-style pneumatic valves, for example). These do not translate to rigid thermoplastics. Similarly, PDMS chips often have features with high aspect ratios that are easy to cast but difficult to demold from a steel insert. DfM review at Micromolds specifically targets these incompatibilities early, before tooling investment. Surface chemistry is the other major transition challenge. PDMS becomes hydrophilic after oxygen plasma, but reverts to hydrophobic over 24–72 hours. Thermoplastics like COC and PMMA can be surface-functionalized using UV/ozone treatment, aminosilane chemistry, or plasma treatment and these modifications are stable, reproducible, and scalable in a way that PDMS plasma activation is not. Recommended transition protocol: (1) Begin with PDMS prototyping of functional architecture. (2) Transition to thermoplastic CNC-milled or micro-milled chips for critical feature validation under production-material properties. (3) Commission prototype injection mold tooling for first production-representative lot. (4) Qualify dimensional stability and assay performance before committing to production tooling. Micromolds supports each stage of this workflow. Applications of Custom Microfluidic Chips Custom microfluidics manufacturing via injection molding has moved well beyond academic labs. Here are the application areas where demand is strongest and where the engineering constraints are most acute: Point-of-care diagnostics (IVD) Lateral flow is mature. The next generation of POC diagnostics requires quantitative, multiplexed detection and that means microfluidic chips. Regulatory path (CE IVD, FDA 510(k)) demands manufacturing controls that only injection molding can deliver: documented tolerances, validated process parameters, lot traceability, and biocompatibility dossiers. COC and COP are the materials of choice. See our PMMA microfluidic chip manufacturing case study for a production-scale example. Organ-on-a-chip and microphysiological systems Organ-on-chip research is transitioning from PDMS proof-of-concept toward commercial instruments. The absorption of lipophilic drugs and signaling molecules into PDMS is a well-documented confound in pharmacological studies. Thermoplastic chips with ultra-low absorption profiles (COC/COP) are enabling the kind of quantitative pharmacokinetic data that drug developers actually need. Digital PCR and nucleic acid analysis Droplet digital PCR (ddPCR) chips require monodisperse droplet generation at kHz frequencies with <2% coefficient of variation in droplet volume. This is a geometry problem at its core, it demands channel dimensional stability that injection-molded thermoplastics provide and PDMS fundamentally cannot guarantee at scale. Cell sorting and single-cell analysis Deterministic lateral displacement (DLD) arrays, inertial focusing channels, and acoustofluidic separation devices all rely on feature dimensions in the 5–50 µm range, with tight tolerances on pillar-to-pillar spacing and channel width. These are exactly the features where injection molding's ability to replicate sub-10 µm structures from a precision-polished insert becomes mission-critical. Industrial and environmental monitoring Continuous flow chemistry, inline analytical devices, and microreactors for process monitoring are driving demand for chemical-resistant thermoplastic chips at high volumes. The economics here strongly favor injection molding over any batch fabrication method once volumes exceed a few hundred units per year. How to Start Your Custom Microfluidics Project The most common mistake: waiting until you're "ready." In practice, the earlier you engage a microfluidics manufacturing specialist, the fewer expensive redesign cycles you'll face. DfM constraints, features that can't demold reliably, wall thicknesses that cause sink marks, gate locations that create weld lines across critical features, are cheapest to address when they're still lines in a CAD file. At Micromolds, the engagement process is designed to move fast: Upload your CAD file or describe your project STEP or a sketch with key dimensions. The Micromolds engineering team reviews for manufacturability and responds with a feasibility assessment and quote. Receive DfM feedback and production quote Within days, not weeks. Feedback covers tooling strategy, material recommendation, and any geometry modifications that improve yield or reduce tooling cost. Tooling fabrication begins All mold design and manufacturing is 100% in-house, CNC milling, EDM, surface finishing, electropolishing, at Micromolds facilities in Lithuania, EU. First parts, inspection, iteration Prototype parts arrive with dimensional reports. Tooling modifications (if needed) are completed in-house, typically within days. No outsourcing lag. Scale to production Once the design is locked, the same tooling infrastructure scales from hundreds to hundreds of thousands of chips without process change or re-qualification. Whether your project is at the napkin-sketch stage or ready to transition from validated PDMS prototypes, the right moment to start a conversation about microfluidics manufacturing is now, not after your next funding round. Not Sure if Your Design Is Ready for Injection Molding? Upload your CAD file or describe your device. We'll review it and send you a feasibility report and quote. Frequently Asked Questions What is microfluidics manufacturing and how does injection molding differ from standard plastic molding? Microfluidics manufacturing refers to the end-to-end process of producing microfluidic chips, devices containing microscopic channels, chambers, and functional features designed to manipulate small volumes of fluids with high precision. Microfluidic injection molding specifically requires ultra-precise mold tooling (EDM-machined inserts), mold temperature control and dimensional verification at the micron level. Standard injection molding handles millimeter-scale features and tolerances; microfluidic injection molding operates at significantly smaller scales and tighter tolerances. At Micromolds, the entire process, from DfM review and tooling development to molding, bonding, inspection, and cleanroom packaging, is optimized for custom microfluidic devices. How small can channel features be in injection-molded microfluidic chips? In standard production, Micromolds typically manufactures microfluidic channels with dimensions ranging from 100–500 µm, depending on geometry, material, and application requirements. For advanced designs, sub-100 µm channels and microfeatures may be achievable through optimized tooling, material selection, and process development. Which materials are best for microfluidic injection molding: COC, COP, or PMMA? The optimal material depends on the requirements of your application. COC (Cyclic Olefin Copolymer) and COP (Cyclic Olefin Polymer) are widely used in microfluidics due to their excellent optical clarity, low water absorption, low autofluorescence, and good chemical resistance. They are particularly well suited for fluorescence-based assays, diagnostics, and life science applications. PMMA (Acrylic) is a cost-effective option that offers high optical transparency and ease of manufacturing, making it suitable for many analytical and disposable microfluidic devices. Polycarbonate (PC) is often selected when higher impact resistance or thermal stability is required. Material selection should consider optical performance, chemical compatibility, bonding requirements, sterilization methods, and regulatory expectations. During the feasibility phase, we help determine the most suitable material for your device and manufacturing goals. Can I transition my existing PDMS prototype directly to injection molding? Often yes, with some modifications. Channel topology, junction geometry, and overall chip layout typically transfer well. Features that rely on PDMS elasticity, such as Quake-style pneumatic valves, need to be redesigned for rigid thermoplastics. Very high aspect ratio features (depth:width > 1:5) may require geometry adjustments for demolding. The good news: these modifications are almost always minor and are identified during DfM review before any tooling is ordered. Most teams are surprised by how straightforward the transition is once they have expert guidance. What are the minimum order quantities for custom microfluidic chips? There is no strict minimum. Micromolds works with R&D teams needing as few as 50–200 prototype chips to validate an assay, all the way through to commercial runs of hundreds of thousands of units per year. Prototype tooling is designed to be cost-accessible for early-stage projects, and the same tooling infrastructure scales to production without process re-qualification. The economics of injection molding become increasingly favorable compared to alternatives once you exceed a few hundred chips per year. How long does it take to get first injection-molded microfluidic parts? Prototype tooling typically takes 1–3 weeks from design sign-off to first parts. Because all mold design, CNC machining, EDM, and surface finishing are done in-house at Micromolds, there are no outsourcing delays or communication gaps. If tooling modifications are needed after first-article inspection, they are usually completed within days. Production tooling lead times are longer but are scoped during the project planning phase so you can align with your development timeline. Does Micromolds offer bonding and full device assembly, or only molded parts? Micromolds provides the full manufacturing stack, including channel layer molding, lid/cover layer production, and bonding. Finished, sealed microfluidic chips are inspected, dimensionally verified, and packaged in controlled environments. Is microfluidics manufacturing from Micromolds suitable for IVD and regulated applications? Yes. Micromolds operates with the documentation and process control discipline required for IVD development, including lot traceability, dimensional inspection reports, and validated process parameters. Material options include grades with established USP Class VI and ISO 10993 biocompatibility dossiers. We work with teams navigating CE IVD and FDA 510(k) pathways and understand the manufacturing evidence requirements those processes demand. Contact us early in your regulatory timeline, manufacturing documentation is far easier to build from the start than to reconstruct retroactively.

Custom injection molded waffle pack trays are often required when standard trays cannot provide the dimensional stability, positioning accuracy, or automation compatibility needed for high-precision electronics manufacturing. As electronics injection molding applications become increasingly automated, handling and packaging solutions must meet the same performance standards as the components they support. Over several years of collaboration, I worked with a global technology company developing connectivity solutions for next-generation AI infrastructure. As their component portfolio expanded and manufacturing volumes scaled, the handling requirements evolved alongside — what began as a targeted development project grew into an ongoing engineering partnership spanning multiple tray generations and component families. Standard waffle pack trays were not sufficient. While widely used in semiconductor manufacturing, they are typically designed for manual handling and lack the dimensional stability required for the precision automated workflows their production demanded. Developing Custom Injection Molded Waffle Pack Trays for Automated Electronics Manufacturing Micromolds co-developed custom injection molded waffle pack trays designed for automated electronics manufacturing environments where positioning accuracy, ESD protection, and repeatable robotic handling are critical. Rather than adapting a standard format, tray design, tooling, and micro injection molding processes were developed to meet these requirements. The project demonstrates how electronics injection molding can be used not only for functional components but also for precision handling and packaging solutions within automated manufacturing environments. Multiple Tray Designs for Different Components The project required more than a single tray design, and over time, that scope grew significantly. As the client's component portfolio developed and production lines expanded, I engineered an extensive range of custom waffle pack trays, each adapted to different component geometries and handling requirements within the same manufacturing ecosystem. New tray variants were developed iteratively alongside component evolution, requiring close coordination between their engineering teams and mine across multiple development cycles. Engineering Challenges in Electronics Injection Molding The project combined many of the challenges commonly encountered in electronics injection molding, including dimensional stability, thin wall geometries, flatness control, and consistent replication of high-density features. Automated handling systems required stable positioning accuracy across the entire tray surface, demanding special attention to: geometry optimisation material selection gate positioning cooling distribution material flow behavior. Thin wall structures and dense feature arrays increased process sensitivity, where even small variations could affect geometry and handling performance. Precision Tooling for Electronics Injection Molding The project required multiple injection molds supporting electronics manufacturing applications, with each custom waffle pack tray designed for specific component geometries and automated handling requirements. Dedicated precision mold tooling was developed to ensure dimensional consistency, flatness, and repeatable production performance across all tray variants. Precision Tooling for Complex Geometry Each injection mold was designed to replicate high-density feature geometry while maintaining dimensional consistency across the tray. Thin wall structures and fine features required tooling capable of producing both detailed geometry and ensuring overall flatness. This was especially important to ensure consistent interaction with automated handling systems across all tray variants. Tooling Considerations Tooling development focused on: accurate cavity machining controlled surface finish alignment of "mold sides" optimized cooling layout effective venting These elements ensured uniform filling behavior and reduced distortion across different tray designs. Tooling for Serial Production All tools were developed for stable serial production rather than prototyping. Consistency between tools was critical, as variations could lead to differences in feature geometry, flatness, or positioning accuracy between tray variants. This would directly affect performance in automated handling systems. By aligning tooling design with part geometry and process conditions, consistent performance was maintained across all tray designs and production batches. Injection Molding as a Controlled Manufacturing Process Precision electronics injection molding was critical to achieving repeatability, dimensional stability, and scalable production. The combination of thin wall geometry and dense feature arrays required tightly controlled processing conditions to ensure consistent product performance. The process was optimized to ensure: consistent material flow across the tray stable thermal conditions proper venting and cooling From Handling Tray to Manufacturing Interface As the collaboration deepened across multiple product generations, the trays evolved beyond simple transport components. Working closely with the client's process engineers, I refined each design iteration based on real production feedback, adjusting retention geometry, flatness tolerances, and alignment features as their automated systems became more sophisticated. The result is not a single product, but a family of precision-engineered trays that together form a reliable manufacturing interface across their entire photonic component portfolio. The final design includes: high density feature arrays custom feature geometry for controlled retention reduced contact areas to protect sensitive features reinforced structure for improved flatness alignment features for automated positioning ESD safe material These features allow stable and repeatable interaction with automated systems. Supporting Automated Electronics Manufacturing As electronics and AI infrastructure manufacturing continue to evolve, production environments are becoming increasingly automated, precise, and demanding. Components, handling solutions, and supporting elements must all meet strict requirements for dimensional stability, repeatability, and seamless integration into automated workflows. At Micromolds, we specialize in precision electronics injection molding and micro injection molding solutions for precision components, automated handling systems, photonics applications, and custom packaging interfaces. By combining tooling expertise, process control, and scalable manufacturing, we help customers develop reliable solutions for demanding electronics manufacturing environments. Conclusion In conclusion, custom injection molded waffle pack trays play a vital role in the automated electronics manufacturing landscape. They ensure that components are positioned accurately and handled safely throughout the production process. By investing in tailored solutions, manufacturers can achieve higher efficiency and reliability in their operations. Frequently Asked Questions What are injection molded trays used for in electronics manufacturing? Injection molded trays are used to position, protect, and transport sensitive electronic, photonic, and semiconductor components throughout manufacturing, assembly, inspection, and packaging processes. Injection molded waffle pack trays provide precise part orientation and compatibility with automated handling systems. Why are custom injection molded waffle pack trays used instead of standard trays? Custom injection molded waffle pack trays are developed when standard tray formats cannot provide the dimensional stability, retention geometry, or positioning accuracy required for automated electronics manufacturing. They are designed around the specific component and production process. Why is dimensional stability important in automated electronics manufacturing? Automated handling systems rely on precise and repeatable component positioning. Variations in injection molded tray geometry can affect robotic handling, vision inspection systems, and assembly processes, making dimensional stability a critical requirement. How does injection molding improve tray consistency? Precision injection molding enables highly repeatable production of injection molded trays with controlled dimensions, stable material behavior, and consistent feature replication. This ensures reliable performance across high-volume electronics manufacturing environments. What materials are commonly used for injection molded waffle pack trays? Injection molded waffle pack trays are often manufactured using ESD-safe engineering plastics to protect sensitive electronic and photonic components from electrostatic discharge. Material selection depends on dimensional stability, mechanical requirements, and manufacturing conditions. What are the main challenges in manufacturing custom injection molded waffle pack trays? Key challenges include controlling warpage, maintaining flatness, achieving consistent replication of fine features, and ensuring dimensional stability across large injection molded tray surfaces. Tooling design and process control play a critical role in overcoming these challenges. Can injection molding support semiconductor and photonics applications? Yes. Injection molding is widely used to manufacture precision injection molded trays, components, and handling solutions for semiconductor manufacturing, photonics, and advanced electronics applications where repeatability and precision are essential. Developing a custom precision component or automated handling solution? Contact Micromolds to discuss your engineering and manufacturing requirements.

Micromolds recently participated in the 3rd UK Microfluidics Conference, hosted at Manchester Metropolitan University. We joined researchers, manufacturers, startups, consultants, and industry professionals from across the UK and beyond. The conference welcomed more than 120 attendees. It featured two keynote presentations, 17 oral presentations, 33 research posters, and 14 exhibitors. This highlighted the latest advances in microfluidic technologies and fostered collaboration across the sector. Ahead of the main conference, Micromolds also took part in the satellite event, "Engaging with the Microfluidics Industry," organized in partnership with the UK Microsystems Network. The session created an opportunity for open discussions between academia and industry. It focused on the practical challenges of translating research into commercially manufacturable products. Early Manufacturing Planning Takes Centre Stage During the satellite event, "Engaging with the Microfluidics Industry," Micromolds CEO Dominykas Turčinskas shared a story from a recent customer project. This highlighted why manufacturing should be considered much earlier in the development process. The example involved a customer who had successfully developed a glass microfluidic chip. This chip had already passed clinical validation and demonstrated excellent functionality. The next objective was to reduce manufacturing costs by transitioning the device to thermoplastic microfluidic injection molding. While the concept appeared straightforward, detailed manufacturing analysis revealed several engineering challenges. These required significant design optimization before production tooling could begin. Among the considerations identified were: Material shrinkage Mold filling behaviour Demoulding constraints Part deformation Bonding tolerances Feature replication accuracy Although the original design performed successfully as a glass device, it had not been developed with high-volume thermoplastic manufacturing in mind. Prototype the Technology One of the key messages shared by Micromolds during the satellite event was simple: Prototype the technology. This message reflected the importance of considering manufacturing alongside functionality from the earliest stages of product development. Too often, manufacturing requirements are introduced only after device performance has been validated. However, for microfluidic injection molding, early design decisions directly influence manufacturability, tooling complexity, production yield, repeatability, manufacturing costs, and ultimately the success of commercialization. By integrating manufacturing expertise early, development teams can reduce technical risk. They can also accelerate the transition from prototype to scalable production. Conference Highlights Beyond the satellite event, the conference showcased the continued growth of the UK microfluidics community. Across presentations and discussions, several industry trends emerged: Commercialization remains one of the biggest challenges facing microfluidic technologies. Earlier collaboration between academia and manufacturing partners leads to more successful product development. Sustainability and manufacturing efficiency must be considered together as the industry scales. These themes reflected a growing recognition that successful innovation depends not only on scientific excellence but also on designing products that can be manufactured reliably at commercial scale. Supporting the Path to Commercial Production At Micromolds, we work with customers throughout every stage of product development. This includes Design for Manufacturing, prototyping, precision micro tooling, microfluidic injection molding, bonding and assembly, and production scale-up. By combining engineering expertise with precision manufacturing capabilities, we help organizations reduce development risk. We also accelerate the path from innovative concepts to scalable commercial production. Looking Ahead The UK Microfluidics Conference 2026 once again demonstrated the strength of collaboration within the microfluidics community. As more technologies move from research laboratories towards commercial applications, integrating manufacturing expertise early in development will continue to play a critical role in successful product commercialization. For Micromolds, it was a valuable opportunity to exchange knowledge, strengthen industry connections, and contribute to discussions shaping the future of scalable microfluidic manufacturing. The Importance of Early Collaboration Early collaboration is essential in the microfluidics industry. It allows teams to align their goals and expectations from the start. This alignment is crucial for successful outcomes. When engineers, researchers, and manufacturers work together, they can identify potential issues early. This proactive approach saves time and resources. Involving manufacturing experts early can lead to better design choices. These choices can enhance product performance and manufacturability. It also helps in understanding regulatory requirements that may impact the design process. Conclusion In conclusion, the 3rd UK Microfluidics Conference highlighted the importance of early manufacturing planning and collaboration. As the microfluidics industry evolves, the need for efficient and reliable production methods becomes increasingly vital. By focusing on early integration of manufacturing expertise, we can help drive innovation and bring complex designs to market effectively. At Micromolds, we remain committed to being the go-to partner for innovative companies needing ultra-precise micro-scale polymer components. We understand the challenges faced in regulated industries and strive to support our clients in overcoming them. For more information about our services, please visit Micromolds or contact our team to discuss your project.

Choosing the right fabrication method is a critical step in microfluidic device development. It affects prototype performance, production cost, scalability, and the transition to commercial production. Hot embossing and micro injection molding are the two most common manufacturing processes for thermoplastic microfluidic devices. Rather than competing technologies, they serve different engineering and production needs. Hot embossing can be used for early-stage prototyping because of its relatively simple tooling approach, but its suitability depends strongly on device geometry and demolding requirements. Micro injection molding offers a broader manufacturing window, supporting production-intent prototyping, pilot batches, and commercial production with high repeatability and dimensional consistency. Prototype tooling also allows engineers to validate manufacturability before investing in production tooling. Understanding hot embossing vs micro injection molding for microfluidic devices requires evaluating more than production volume or initial tooling cost. The Microfluidic Device Development Process Microfluidic device development typically progresses through multiple engineering stages before commercial production: Concept → Design → Prototype Fabrication → Functional Testing → Design Optimization → Design for Manufacturing (DfM) → Tooling → Pilot Production → Commercial Manufacturing The choice of fabrication method depends on more than production volume. As projects mature, engineering priorities shift from validating functionality to evaluating manufacturability, assembly, bonding, material performance, and process capability. Hot embossing can support early-stage development particularly well for relatively planar microfluidic designs with surface microstructures that can be replicated and released from the tool without excessive mechanical stress. Suitability becomes more challenging with deep or high-aspect-ratio channels, undercuts, steep or complex sidewalls, dense microfeatures, and geometries that generate high demolding forces. In these cases, deformation, feature damage, or dimensional variation can occur during part release. Micro injection molding can be introduced during development when the prototype needs to more closely represent the final commercial product. It allows engineers to evaluate production-relevant factors such as mold filling, gate and vent locations, shrinkage, ejection, bonding surfaces, integrated ports or reservoirs, and overall dimensional repeatability before committing to production tooling. Selecting the appropriate fabrication method at each stage helps reduce development risk and supports a smoother transition to commercial production. Learn more about microfluidic prototyping and how early manufacturing validation supports production readiness. Micro Injection Molding for Microfluidic Device Manufacturing Micro injection molding is a manufacturing process used to produce high-precision thermoplastic microfluidic devices. Molten polymer is injected into a precision-engineered mold under high pressure, where it fills micro-scale features before cooling and solidifying into the final part. Micro injection molding can support a broad range of development and production stages, from production-intent prototypes and pilot batches to serial and high-volume manufacturing. This makes it particularly versatile for projects that require the manufacturing process to scale without fundamentally changing the replication technology. Prototype tooling enables engineers to manufacture production-intent parts that closely replicate final production conditions, allowing early evaluation of manufacturability, dimensional accuracy, material performance, bonding, and assembly. Once the tooling and process are validated, controlled injection parameters also support consistent replication across repeated production cycles, which is critical when moving from development into commercial manufacturing. It also enables complex three-dimensional features, such as reservoirs, ports, mounting elements, and alignment features, to be integrated directly into the molded component, reducing the need for secondary operations. However, these advantages come with greater engineering complexity. Successful micro injection molding depends on factors such as mold design, polymer flow behaviour, gate and vent design, cooling strategy, shrinkage control, and process optimization. Decisions made during product design can therefore have a significant impact on manufacturing performance, quality, and production cost. For many microfluidic products, the question is not whether micro injection molding is the right fabrication process for the device, but whether it should be introduced early enough in development to reduce technical risk before production tooling is commissioned. Hot Embossing for Microfluidic Device Manufacturing Hot embossing is a replication process in which a heated thermoplastic substrate is pressed against a precision master mold. Under controlled temperature and pressure, the polymer softens and accurately replicates the mold's micro-scale features. Hot embossing can replicate fine surface features using relatively simple tooling, making it suitable for certain microfluidic geometries and development applications. However, its applicability is more design dependent than micro injection molding, particularly when devices require complex three dimensional features, controlled demolding, or consistent replication across repeated production cycles. Hot embossing works best for predominantly planar microfluidic geometries. Features that extend significantly out of the embossed plane, such as deep reservoirs, fluidic ports, bosses, and complex alignment structures, are difficult to create in the same embossing step and usually require secondary machining or separate components. Demolding is an important limitation in hot embossing. Because the polymer must be mechanically separated from the embossing tool after replication, features such as deep channels, high-aspect-ratio structures, near-vertical sidewalls, undercuts, or densely spaced microfeatures can generate high release forces. This can lead to deformation, surface defects, damaged microfeatures, or material remaining on the tool, making dimensional control and repeatable replication more difficult. One advantage of hot embossing is relatively simple tooling for predominantly planar device designs. However, this benefit decreases when the part requires geometries that are difficult to demold, additional three-dimensional features, or secondary operations to complete the device. From a production perspective, hot embossing has both advantages and trade-offs. Conventional hot embossing typically has relatively low throughput because each cycle requires heating, embossing, cooling, and demolding. In contrast, roll-to-roll or rotary hot embossing can achieve very high throughput when the product can be manufactured in a continuous web format. This approach is best suited to thin thermoplastic films or sheets with predominantly surface-relief microfeatures and geometries that can be replicated and released continuously from the tool. Discrete thick parts, deep three-dimensional features, undercuts, or geometries requiring complex demolding are generally less compatible with continuous embossing. Therefore, the throughput advantage of hot embossing depends strongly on the product format and geometry rather than on the process alone. Comparing Hot Embossing and Micro Injection Molding When comparing hot embossing vs micro injection molding for microfluidic devices, engineers should consider device geometry, demolding, repeatability, feature integration, production volume, and long term scalability. Engineering Consideration Hot Embossing Micro Injection Molding Primary engineering objective Replication of suitable surface microstructures, development applications, and high-volume continuous replication where the product is compatible with roll-to-roll processing Production intent prototyping, manufacturability studies, pilot production, and commercial manufacturing Production strategy Suitable for selected development and commercial applications where device geometry supports reliable embossing and demolding. Roll-to-roll variants can provide very high throughput for compatible products. Suitable from production-intent prototypes to commercial and high-volume production, with tooling strategies adapted to the development stage and required production volume. Tooling approach Master molds, nickel shims, silicon masters, or precision metal inserts Aluminium prototype molds, steel production molds, precision nickel inserts, and hybrid tooling strategies depending on project requirements Initial tooling investment Generally lower initial investment with relatively simple tooling modifications during development Investment depends on the tooling strategy. Prototype tooling reduces initial cost, while production tooling is optimized for long-term performance and durability Manufacturing economics Lower tooling investment makes the process well suited for iterative development and lower production volumes Overall manufacturing cost depends on tooling strategy, product lifetime, production efficiency, and total demand rather than production volume alone. Cycle time Typically longer because each embossing cycle includes heating, embossing, and cooling Generally shorter because the molding process operates as a continuous production cycle after process stabilisation Feature integration Excellent replication of surface microstructures. Additional features may require secondary machining or assembly operations. Microstructures and functional three dimensional features can often be integrated into a single molded component, reducing secondary operations Replication fidelity Excellent replication of microchannels and fine surface features Excellent replication when tooling design, material selection, and process parameters are properly optimised Process repeatability Repeatability depends strongly on thermal control, embossing conditions, feature geometry, and reliable demolding Very high process consistency across extended production runs when the tooling and process are properly validated Design flexibility Tooling modifications are generally faster and less expensive, making iterative development more straightforward Design changes become more complex as tooling progresses from prototype to production, although prototype tooling remains comparatively flexible Material compatibility Commonly used with COC, COP, PMMA, PC, PS, and other embossable thermoplastics Compatible with a wide range of injection moldable engineering and medical grade thermoplastics including COC, COP, PMMA, PC, and PS Design for Manufacturing (DfM) Recommended to improve manufacturability and reduce downstream processing Essential for achieving reliable mold filling, repeatable production, robust tooling performance, and long-term production efficiency Demolding Can be challenging for complex or high aspect ratio features. Poor demolding can cause deformation, surface defects, or damage to replicated microfeatures. Mold design, draft, ejection strategy, material behavior, and process control are engineered to support consistent part release. Typical applications Feasibility studies, proof of concept devices, functional prototypes, pilot production, and selected commercial microfluidic products Production intent prototypes, Lab on a Chip devices, molecular diagnostics, point of care diagnostics, disposable cartridges, life science consumables, and commercial microfluidic products Hot embossing and micro injection molding should not be viewed as sequential manufacturing steps. Both technologies can be used throughout the product development lifecycle, depending on the engineering objectives and manufacturing strategy. In many cases, prototype micro injection molding is introduced early to evaluate manufacturability, material behaviour, bonding, and assembly long before commercial production begins. The choice of microfluidic mold tooling also influences how efficiently a design can progress from initial validation to repeatable production. Design for Manufacturing in Hot Embossing and Micro Injection Molding Whether a microfluidic device is manufactured by hot embossing or micro injection molding, Design for Manufacturing (DfM) plays a critical role in product success. Many redesigns occur because manufacturing constraints are considered too late. A device that performs well in laboratory testing may still be difficult to manufacture consistently, particularly when transitioning to production. For both fabrication methods, early DfM helps optimise: Microchannel geometry Wall thickness Polymer flow Material selection Bonding surfaces Tooling strategy Manufacturing repeatability When micro injection molding is selected, additional considerations such as gate location, venting, cooling, shrinkage, and mold design become increasingly important. Applying DfM early reduces engineering changes, lowers development risk, and helps ensure a smoother transition from prototype to commercial production. For further information on polymer selection and processing requirements, explore our injection molding materials. Choosing Between Hot Embossing and Micro Injection Molding There is no universal answer to hot embossing vs micro injection molding for microfluidic devices, because the appropriate process depends on device geometry, required quality, production volume, and manufacturing strategy. Micro injection molding is generally the more versatile option when a project requires production-intent prototypes, complex integrated features, repeatable quality, and a scalable path toward commercial production. Hot embossing remains attractive for specific device geometries and can offer significant throughput advantages when continuous processes such as roll-to-roll embossing are technically suitable and very large production volumes are required. Frequently Asked Questions Can micro injection molding be used for prototype microfluidic devices? Yes. Prototype tooling, including aluminium molds, steel molds, and precision nickel inserts, can be used to manufacture production intent parts for design verification, manufacturability studies, pilot production, and low volume manufacturing. Is hot embossing only suitable for prototypes? No. Hot embossing can be used for both development and commercial manufacturing, but its suitability depends strongly on device geometry and the embossing method. Continuous technologies such as roll-to-roll embossing can achieve very high throughput for compatible products, while conventional hot embossing is generally more limited by cycle time and demolding requirements. Which process provides higher accuracy for microfluidic devices? Both processes can replicate micro-scale features, but achievable accuracy and repeatability depend on the complete manufacturing system. Hot embossing is particularly sensitive to thermal conditions and demolding behavior, while a validated micro injection molding process can provide highly consistent dimensional replication across repeated production cycles. Is micro injection molding only suitable for high volume production? No. Although micro injection molding is widely used for commercial manufacturing, prototype tooling allows it to be introduced much earlier in product development. It is frequently used to evaluate manufacturability, assembly, bonding, and process capability before production tooling is commissioned. Which fabrication process is more cost effective? The answer depends on the project's objectives. Hot embossing generally requires a lower initial tooling investment, while micro injection molding can reduce part cost and improve manufacturing efficiency as production volumes increase. The most economical solution depends on the development stage, tooling strategy, and long term manufacturing goals. How do I choose between hot embossing and micro injection molding for microfluidic devices? The most appropriate fabrication process depends on the engineering objectives of the project. Factors such as design maturity, material selection, manufacturability, production strategy, budget, timeline, and long term commercial goals should all be considered when selecting the most suitable manufacturing process. Conclusion When evaluating hot embossing vs micro injection molding for microfluidic devices, micro injection molding generally provides greater versatility across development and commercial production, while hot embossing can offer significant advantages for specific product geometries and very high volume continuous production. Micro injection molding offers greater versatility across the product lifecycle, from production intent prototypes and pilot batches to commercial manufacturing. It supports complex integrated features, high process repeatability, consistent part quality, and scalable production without requiring a fundamental change in manufacturing technology as volumes increase. Hot embossing can be an effective alternative for specific device geometries, but its suitability is more dependent on feature design, demolding requirements, and the overall product format. For compatible products, high throughput technologies such as roll to roll embossing can provide significant advantages at very large production volumes. For most projects, the decision should therefore be based not only on initial tooling cost or production volume, but on whether the selected process can reliably deliver the required geometry, quality, repeatability, and scalability throughout the product lifecycle.

At Micromolds, precision manufacturing is built on more than technology, equipment and processes. Behind every precision mold, micro-molded component and customer project is a team of people working together. At the end of August 2026, the Micromolds team stepped away from the usual working environment for a day focused on teamwork, communication and a bit of friendly competition. It was a chance to strengthen the teamwork behind our everyday work — just in a very different setting. Team Building Through Military Training and Airsoft The first part of the day took us outdoors for military-style team training. Working through practical exercises gave everyone an opportunity to communicate, coordinate and solve challenges together in an environment very different from our everyday work. Then it was time for airsoft. Split into teams and equipped for the game, we swapped our usual work environment for camouflage, tactical gear and a completely different kind of challenge. Strategy mattered. Communication mattered. And, as we quickly discovered, so did knowing when to move and when to stay behind cover. There was plenty of competition, but even more laughter along the way. After an active day outdoors, we ended the evening around the fire — sharing impressions from the day, relaxing and simply enjoying time together as a team. The People Behind Precision Manufacturing Micromolds works with demanding projects in micro injection molding, precision tooling and microfluidic manufacturing, where collaboration between different areas of expertise is essential. Engineering, production, quality, operations, sales and marketing may have very different responsibilities, but ultimately we are working toward the same goal: delivering reliable, high-precision solutions for our customers. In precision manufacturing, that collaboration matters. Projects involving small and complex plastic components can require close coordination across component design, mold engineering, material selection, manufacturing processes and quality control. Clear communication between teams helps turn individual expertise into a reliable manufacturing process. Teamwork Beyond the Workplace Strong collaboration is not created only during projects, production meetings or technical discussions. It also comes from knowing the people you work with, communicating openly and building trust across different areas of the company. Of course, a day of military exercises and airsoft is very different from designing precision molds or manufacturing microplastic components. But some principles felt surprisingly familiar: communicate clearly, understand your role, adapt when circumstances change and work toward a shared goal. Micromolds Team Day gave us an opportunity to step outside our usual environment, take on a different challenge and have some fun along the way. A big thank you to everyone who joined, competed, laughed and made the day memorable.

During the meeting cluster members discussed on the cluster future strategy 2022-2024. The meeting agenda: goal of the cluster, value creation chains, funding options, financial planning, strategy tracking and control. As the main goal of the cluster it was agreed that CoMI members will seek a leadership in resilient and adaptive manufacturing which is compliant of ManuFUTURE 2030 strategy. In the long term the cluster will be integrated in EIT manufacturing ecosystem and other DIH networks and in this way cluster will assure its internationality and competitiveness across the Europe. According to Mr. G. Vilda (the head of cluster coordinating company), production has long gone beyond the boundaries of factories and is related to network and dynamic value creation systems that can be organized in multiple ways. Aligning and adapting different value creation systems to specific needs and key conditions contributes to building a sustainable and resilient European manufacturing ecosystem in a dynamically changing and uncertain world. The cluster was established in 2020. Its main goal is to unite companies of different sizes, the academic community, associations and other organizations into a club of leaders in manufacturing innovation. Cluster members seek to: increase horizontal and vertical integration between manufacturing industries; pursue the transformation of industry into a high- and medium-high-tech industry through the development and deployment of digital and green technologies; increase the production and export of high value-added products; create preconditions for increasing the international competitiveness of the cluster members and the entire manufacturing sector of the country. The innovative manufacturing cluster aims to become an international cluster and offer more opportunities for the international development and activities of its members. The main activities of the Cluster are as follows: Development of general R&D infrastructure International networking and partner search Construction project funding, search for funding Initiation of cluster projects Representing the interests of members at national and international level General employee competence development events Co-marketing projects Development, publicity and popularization of policy guidelines for the promotion of innovation in manufacturing Production digitization projects

Medical Injection Molding Project MFI (Medical, Industrial) provides design, engineering and production services in Medical and Industrial fields covering high-end on-demand manufactured cables and wires. The company specializes in custom wire harness, assembly of connectors, EEG caps, cable design, soldering fine wires and much more. MFI is a company that has a 15 years of expertise in the medical and industrial fields. MFI has established its name in custom-made wires, electrodes, and similar products categories. MFI has a dedicated team of engineers who are experts in 3D modelling, mechanical engineering, prototyping, and manufacturing. All this is for the creation of a reliable connection for the client. Subcontracting Molding Service When it comes to subcontracting with other manufacturing companies there is always some curiousity to find out something similar between the partners. We were glad when we knew that we have much in common with cable overmolding - even though Micromolds company specializes in micromolding technology, we have had some cable overmolding projects in the past as well. Maybe this much related subject helped as to bond and develop a stronger partnership with other projects to come in the future. Receiving an RFQ This cooperation itself was about injection moulding of a plastic housing for the electrode. As soon as we received the RFQ we understood that this is something we can surely do without much competition, because we could check-mark all of the below: The part was small enough so we could make even 8 or 16 cavities in a single micro mould; The manufacturing volume was up to 100k; It had some micro-features achievable only with micro moulding technology Urgency - the project had to be done in few weeks and it needed rapid prototypes We had in stock medical grade ABS material. The product was an ideal for our micromolding technology and thus we felt quite sure that we can give a competitive offer for the client. DFM analysis and part optimisation for moulding After the order confirmation, as always the DFM followed. Since the contracting company was a manufacturer and had a strong engineering knowledge itself, the quality of the CAD model was superb. As well as the RFQ received itself. “This is what we call a qualitative RFQ that helps to save time for both of the client and the manufacturer” – says CEO Jonas We had only to add some draft angles for some regions and also agree on injection points and ejector marks. The process was fast and smooth and thus we transitioned to the tooling stage in about 3 days. The Tooling – Mold Making We used aluminium micro molds with 4 cavities. No EDM machining was required. We had molds ready in less than 1 week for sample molding. Sample Check T1 When we mold the samples we are the first ones that can inspect them and tell the quality of the work done. As always, we are honest and transparent with the client and if needed we share optical images or videos of the defects occurred. However, the defects can be of 2 types: caused by the moulder (us) or by the client – design of the part. In this case when we received the first feedback there could be controversial opinions: the broken wall could have occurred due to the wrong knit line location (bad part optimisation – our responsibility) or bad design (client’s responsibility). Thanks to the expertise of both the client’s and ours engineers we could nicely agree that this was not an issue of a knit line which was not possible in this situation, as seen in the picture. Both parties could agree that the wall should be thickened and thus the solution to the challenge came quickly. As the CEO of MFI Ronald de Vreeze would say: “We have a solution for just about every challenge – be that specialist customization in single pieces or large volumes…” When it comes to the mold modification due to the subtractive type of CNC machining we can only carve out the material from the mould but not add it back. Since the wall had to be thickened the modification was a minor change and we did it in few days. The results Since the changes were obvious and minor the client decided to avoid the sample check T2 and we went straight to manufacturing of the first batch. Even though we had some little anxiety after we had sent the first batch we received another order for batch 2 and the anxiety dissipated instantly as the results were satisfying. Not only did we succeed in this single project but we have also built a strong partnership with a MFI company – we are having next 2 projects to come and we take this as prove that we did a truly great job.

The Allergomedica (UAB Imunodiagnostika) clinic is an innovative place where not only comprehensive and professional help can be provided for the patients but also novel health monitoring solutions are developed. The clinic specializes exclusively in the diagnosis and treatment of allergic diseases. Allergists and clinical immunologists, laboratory specialists, and researchers work together to address each patient’s individual problem. Knowledge about allergic diseases and their diagnosis is constantly changing. New and new ways of treatment and diagnosis are emerging, so the highest quality care can be provided to the patient only by specialists who are constantly improving in this field. Health Tests at Home One of the newest innovative initiative of the clinic was to provide patients an opportunity to perform health tests at home with the use of simple blood test kits which can be shipped from home to the clinic for research. To develop such kits Allergomedica has chosen Micromolds as a design and manufacturing partner. The kit hardware consisted of a plastic stick to collect the test samples and the plastic case where the stick would be safely located for the transportation. It required a close teamwork of the clinic medical specialists and Micromolds engineers to design and make the first prototypes of the plastic hardware. The SLS printed prototypes For the first prototypes we used 3D SLS printing technology just to get the feel and look of the plastic case and the stick inside of it. Also, we had to check the assembly and fit of the assembled parts. It was also, necessary to assure a good snap fit of the closing parts of the case. Aluminum Micro Molds for Low-volume Production When the prototype versions were confirmed for further manufacturing we had to make a transition to the tooling and moulding of the first batch. For the tools, as almost always, we used aluminium and EDM machining to achieve desired surface finish of the final plastic cases. The results The plastic cases were delivered on time and in a good quality. We have many more projects to come with this innovative clinic and we take this as a proof of our good work.

„Ruptela“ - one of the fastest growing high-tech companies in Lithuania, providing transport management solutions. The company, which has been operating since 2007, manufactures integrated transport telematics equipment. These devices consist of GPS tracking devices, real-time monitoring and control systems. The company works with partners and clients in 127 different countries and helps companies optimize transportation processes. This is not a first time „Ruptela“ has chosen us, as reliable sub-contractors. We have been designing 3D CAD models optimized for manufacturing for their products’ positions for several months. This time we have been contracted to design the new housing of the „Pro5“ vehicle tracking model. “Micromolds” was responsible for product design, its optimization for manufacturability, mould design and prototype production. Design Constraints The main design constraint of this project was that the designed housing had to conform SAE J1455 recommendations for vehicles. These recommended areas of practice cover variety of concepts, affecting electronic equipment for heavy vehicles. Some environmental factors that had to be considered during product development are: Temperature; Moisture; Atmospheric effects; Mechanical vibration and mechanical shocks. The most challenging thing was to create an extremely tightly closing housing which could be opened without any tools. The housing had to be without any additional components - everything had to be integrated. We have decided to design external hooks to fulfill this need. It was possible to open the housing box by hand, without any additional tools. The housing also had to be a good electrical insulator, fireproof and impact resistant. For these specifications and design requirements we have chosen to use PC Lexan (Lexan® Polycarbonate) plastic material. One more design requirement was to integrate LED indicators inside the housing. The material we chose was semi-transparent so it was possible to let the LED indicators light directly through the wall of the housing. Prototyping Like in every our previous similar projects we used 3D printing FDM (fused deposition modelling) technology for prototype manufacturing. It was used for the initial evaluation of the product. After we had indicated the flaws of the prototype and made some design tweaks we went for second trial. Second prototype made with SLS (selective laser sintering) 3D printing technology was used for more accurate functionality and user experience testing. To get more realistic look and feel of the final product we made third prototype with another one 3D printing technology – SLA (stereolithography). Third prototype was also painted black to resemble final product we were striving for. Rapid prototyping technology made it possible to quickly check the functionality and the look of the product. These 3 iterations of prototyping made our team and contractors confident to scale for the serial production of this housing. SLS 3D Printed Prototype Manufacturing Plastic injection molding was the only manufacturing technology solution for mass production. Even though these housings were outside our micro-mould size limits, we successfully designed this product, optimized it for manufacturability, produced prototypes and manufactured moulds with our CNC machines. We are glad that we are trusted by such innovative companies like “Ruptela” and could strongly contribute to their new product development. Final Injection Moulded Housing

New product releases and innovation are inevitable actions for the growth of the company. And not only this. During the period of the pandemic, fast and resilient companies contribute to the long-lasting fight against covid-19 with their solutions. Recently, "Micromolds" has had a contract to mould plastic components for our client's Bacteo newly developed product - a portable UV lamp. About our client During the first hit of the coronavirus, three entrepreneurs noticed that there either is a deficit of a disinfecting technology - Ultraviolet Light (UVC) - against covid-19 in the market or existing UV lamps are not efficient enough. To solve this problem Bacteo company was established to create safe and user-friendly UV lamps that would help disinfecting large areas during the global pandemic. Disinfection lamps kill harmful microorganisms with a short-wavelength ultraviolet light and it is scientifically proven that this method is also effective for inactivating viruses, including coronavirus. These UV lamps may be used in various public institutions to clean the infected surfaces and reduce the spread of the virus. Disinfection lamp We are proud to have contributed with such an innovative and socially responsible company to turn its ideas into reality and we will soon explain how. Plastic Spacer and The Cover After we had received CAD drawings of the part, our engineers had already started to design the moulds for injection molding and optimize for manufacturability. The material used is ASA (acrylonitrile styrene acrylate). This plastic is similar to ABS but has better weather, especially UV resistance, thus this material is widely used for outdoor products. The picture below shows the part and the mould together still in the design phase. Designing Mould Core Side and Part ASA material was also used for the plastic cover as well as for cover undercuts. Since the project was on a strict schedule there was a lack of time for testing and prototyping. Tooling process was also done rapidly. Since the estimated production levels were not large, we decided to use manually operated inserts to form undercuts instead of inclined ejector pins. Designing Mould Core Side and Part It was difficult to guess how tight the undercuts should hold the cover in position. We were told that the cover should not be easily detachable as it will be used as an exterior component, however, it must be detachable if service for the product would be needed. We decided to go through empirical practice and prototype “on the go” within the mold itself because we had an opportunity to cut deeper into the core to shape higher ribs which would increase rigidity of the undercuts. After the first try we immediately noticed that the hooks were too loose, thus we agreed to increase the height of the ribs by milling a deeper mold section marked in red. After the second trial the undercuts were successfully shaped in required tightness and the production launched. We are happy that we are able to help companies to maintain their resilience and ability to rapidly adapt to the market changes and capture given opportunities, moreover, to contribute to the overcoming of this COVID pandemic period and the improvement of people's health.

We are proud to share that our most recent micro injection molding project has allowed us to put our passions for challenges and sustainability in one place by collaborating with innovation and environmental friendly company. However, as nothing good comes easy, this project brought us to a great challenge which will soon be introduced further. About our client Since 1825, MyCourant is a rope and rope accessories manufacturer located in France. Courant is a vertical living and safety brand name well-known worldwide. This is a family business where the know-how was accumulated through almost 200 years and was conveyed and developed from generation to generation. The innovation lies deep in the roots of this company and this project is not an exception. Main Challenges: Design and Sustainability This time MyCourant team was developing a new “Boule de Ferlette” for recall ropes. It is a ball that is placed in the end of the recall rope for the recovery of false ring fork. This ball is useful during pruning work and can be used even if the rope does not have a splice. In order to have a better picture of how the "Boule de Ferlette" will look like after the process of injection molding, the first 3D printed prototype was created. 3D Printed Prototype However, the initial solution of a wooden anchor with a special surface treatment appeared to have serious drawbacks. The surface treatment was mainly used for better wear resistance and brighter colors, but this made the ball a non-ecological product and too simple in its shape. Basically, it did not represent the company as needed as it had not aligned with one of the main values - sustainability. “in order to have reasonable costs, we could not do what we wanted in terms of shape since the machining of a product would be complicated but the worse was that it deteriorated quickly, and we had long production times”, - stated the R&D designer Mr. Laurent Glauser. The new approach: Biodegradability and Design for Manufacturability The new design was based on biomimicry and thus, aligns better with the company’s values. Mr. Laurent has worked hardly on a new design to make the product similar to the acorn and manufacturable. Mr. Laurent has previously stated that: “The product should not get stuck through foliage or branches and therefore should be profiled.” The ball had additional design constrains – the strong construction which would be able to withstand at least 200 Kg and ecological materials used, as Mr. Laurent has stated: “Biodegradability is important since the future is green and ecology is a subject close to our hearts and to our customers”. 3D Prototyping for Injection Molding Low-Volume Manufacturing: Micro Injection Molding Right after the new designs were developed, tests were made on ground with professional users and stress tests were conducted with a test bench on 3D printed models. When stress analysis was passed, Mycourant team contacted Micromolds company for the service of injection molding. Since Micromolds company specializes in low-volume manufacturing and micro injection molding, the “Boule de Ferlette” project was a well targeted RFQ. The quote with moldability analysis was sent through 1 business day and the new issue arose: making the design of a ball compatible with injection molding technology. Challenge No.1 - Undercut Regions Undercut Regions and Moldability Analysis The ball had many undercut regions. This might happen with the new projects and sometimes it is worth to remember, that not everything that is visually attractive can be manufactured. The rope that was winded around the ball had to be shifted to avoid undercuts. Micromolds came up with 3 new design solutions. Challenge No. 2 - Sink Marks Thick Wall regions and Sink Marks - Moldability Analysis Making Walls Thinner Since the ball had thick wall regions, there was a considerable risk of material cooling issues which would cause sink marks to achieve better strength. In injection molding, thick walls do not always mean strong walls. Sinking can cause serious problems and can hugely reduce the strength of the part. Engineers and designers had to agree on where exactly and which walls can be thinner as well as what hollowing options were possible to maintain a good appearance of the product. Challenge No. 3 - Mold Modification After the first sample check and tests, MyCourant company came up with a complicated modification in mind. When it comes to modification in injection molding, the possibilities are bounded by the exact location and type of the modification in the mold. Since the tooling process is done by the means of material subtraction – CNC machined, this means that the processes cannot be rewinded. In simple terms - the metal chips cannot be glued back to the mold. So, if the modification takes place in the cavity side, enlarging the wall, for example, may be possible because the mold can still be machined. However, if thicker wall is needed in the core side, this might become impossible, since there might be no material left to machine. In this case, modification happened to not be in favor for the Courant company. Section view of the Molded Part - Version 1 Micromolds loves challenges and took risk by trying to do the impossible. It would actually not be possible to put those machined chips back, though machining a little ‘puzzle’ part that could be glued or screwed inside the core side of the mold might seem as a way out. This solution can work in rare cases and is purely dependent on the luck – where the modification takes place. The way around this problem was smooth – the mold was modified and the production was launched. Mold Modification Screw Mold Modification Screw from the inside Results: Final Injection Molded Products and Smooth Collaboration The cooperation with MyCourant company was smooth and satisfying. Brilliant and fast communication laid a strong foundation for trust between both companies. Altough the project has had many challenges and has taken a long time to be finished, both parties are equally satisfied with the results. Mr. Laurent’s feedback illustrates this nicely: “We are happy with the result and the quality of the parts obtained, with a biodegradable and compostable material, still young on the market. In addition, Micromolds provided an excellent service and cost-saving advices.” Final Injection Molded Parts

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