Value-added Micro Injection Molding Maker

Professional Micro Injection Mold Manufacturer

Micro-injection molding is a precision molding process in which proper mold design and control of every step of the manufacturing process are critical to the success of the microforming project. Kemal has in-house strengths in mold design, manufacturing, and inspection, which gives us a outstanding advantage in handling extremely tight tolerances and complex specialty products. The ultimate goal is to deliver a high quality product to the customer without any delay. In addition, Kemal has strict quality assurance, which is essential for any microforming operation. Adopting high precision gauge pins for Measurement, so that you can receive 100% satisfaction product.

Micro Injection Molding Parts

Kemal can produce extremely small products with strict tolerances, they are widely used in medical, automotive, aerospace, electronics, communications, defense, and general industry.

Why choose Kemal Make Micro Injection Molds

Kemal’s goal is to build a business based on the manufacturing of high-quality micro injection molding by a high-quality person who will take pride in Kemal. Our team has the same passion for making a quality product, and that in turn leads to a higher quality output for you.

Meanwhile, we also pride ourselves on our ability to meet all production deadlines without any surprises or unexpected problems, so you can expect your products to arrive on time.

Contact us and make an appointment for obligation-free advice.

Contact Our Professional Team

Kemal Your realiable Micro Injection Molds Manufacturer

Kemal is a leader in the field of micro-injection molding specialization. We have the ability to produce tiny parts with intricate details and characteristics. Kemal can provide complete design and engineering services, from part conceptual design to 3D CAD modeling, to complete tool design, mold manufacturing, and on to mass production.

We also build low-cost prototype molds and test designs prior to production. To minimize production costs and maximize part performance.

If you have any micro-injection projects, find the most suitable supplier from China with satisfactory service. Kemal is your trusted supplier of plastic micro-injection molded parts and services. Contact us today, we will be one of your best choices.

More Questions You May Ask

What’s materials best for Micro Injection Molding?

POM, PC, PMMA, PA, LCP, PEI etc.

What about the size of Micro Injection Molding?

Micro molding generally refers to the injection molding method used to mold products with micron size and milligram mass.

What’s the advantage of Micro Injection Molding ?
  1. the small size helps to improve the balance of the mold, improve the appearance of the product size accuracy;
  2. easier to control the stability of the mold temperature, in line with the requirements of precision molding, but also saves the mold heating/cooling energy required;
  3. low cost of the mold, short development cycle.
What’s the disadvantage of Micro Injection Molding ?

The runner is large, and in some cases, the material in the runner can account for up to 90% of the total injected weight. The runner material is not recyclable in most cases. So the material waste is significant;  In addition, because the surface/volume ratio of micro-injection products is typically high, the mold must be heated above the melt temperature during the injection process to prevent early curing, resulting in longer production cycles.

 

Send Your Inquiry Today

MICRO INJECTION MOLDING: THE ULTIMATE FAQ GUIDE

As a professional Micro Injection Molding manufacturer with 24 years of experience. Kemal pays 100% passion to serve you well.
Here is the FAQ list of the Micro Injection Molding. You could check any question about the Micro Injection Molding that you would like to know.
Such as:
What plastic materials can be used for micro injection molding?
What are the advantages of micro injection molding?
What are the main disadvantages of the Micro Injection Molding Process?

For further communication just feel free to Contact Kemal Team.

Here is the FAQ List:

1. What products are Micro Injection Molding typically used in?
2. What is the classification of Micro Injection Molding Products?
3. What are the equipment requirements for micro-injection molding?
4. What are the characteristics of mold design for micro injection molding?
5. Which equipment is essential for the correct production and collection of micro injection molded products?
6. Which equipment is essential for the correct production and collection of micro injection molded products?
7. What plastic materials can be used for micro injection molding?
8. What are the advantages of micro injection molding?
9. What are the main disadvantages of the Micro Injection Molding Process?
10. What are the special molding processes in micro injection molding?
11. What are the mold design considerations for micro injection molding?
12. What is the difficulty of micro injection mold manufacturing?
13. What technologies are currently used for the processing of micro-cavities manufacture?
14. What are the micro special machining techniques used to process the cavity of the micro injection mold?
15.What are the control methods of micro injection mold temperature?
16. What is the range of application of Micro Injection Molding?
17. What are the equipment requirements for micro-injection molding?
18. What are the key points of the micro-injection molding process?
19. What are the advantages of micro-injection molding?
20. What are the disadvantages of micro injection molding?
21. What are the challenges of micro injection molding?
22.What are the considerations for Mold Components in micro injection molding?

 

1.What products are Micro Injection Molding typically used in?

The products that Micro Injection Molding are typically used in:
The Micro-Injection Molding shows rapid growth in the areas of optical communication, computer data storage, medical technology, biotechnology, sensors and actuators, micro-optics, electronics, and consumer products, as well as manufacturing and mechanical engineering.
Typical examples include watches, camera components, equipment, acceleration and distance sensors, hard disk and CD-ROM drive read-write heads, medical sensors, micropumps, spool, high precision wheels, pulleys and spirals, optical switches and plugs, micromotors, surgical instruments, and communications products.

 

2.What is the classification of Micro Injection Molding Products?

The classification of Micro Injection Molding Products are as below:

1) Micro injection molded products weighing from a few micrograms to a fraction of a Gram, possibly in the micron (mm) range.

2) Injection-molded products of conventional size, but with a microstructural area or characteristic area, such as a disc with a data point gap, a lens with micro surface characteristics, a thin section for manufacturing micro gears using plastic sheet technology, etc.

3)High-precision products with any size but the dimensional tolerance is in the micron level, such as connectors for optical fiber technology.

 

3.What are the equipment requirements for micro-injection molding?

The equipment requirements for micro-injection molding are as below.
1) Accurate injection volume control and ideal injection speed.

2) A small plasticizer shall be used with a screw diameter ranging from 12-18mm and a shorter screw length with an L/D ratio of about 15 to avoid long residence time causing material degradation.

3) Multiple controls can be performed, such as the conversion from mold filling to pressure holding according to both screw position and cavity pressure.

4) The mold temperature is adjustable, with the ability to raise the mold wall temperature to a certain level, sometimes slightly higher than the melting temperature of the polymer, in order to avoid the early curing of the ultra-thin part. If the wall thickness of the micro injection molded product is less than 5mm, the ability to extract the mold is required, because in this case, the wall thickness is on the same order of magnitude as the air escape pore size.

5) Switching nozzles are recommended to avoid melting due to high processing temperature

6) Precise positioning and gentle mold switching speed to avoid deforming delicate micro injection molding parts.

7) Special operation techniques are used to remove the molded parts for inspection and packaging.

8) Prepare a clean enclosed place or a layered turnover box on the spot as far as possible to avoid contamination of micro injection molding parts.

 

4.What are the characteristics of mold design for micro injection molding?

The characteristics of mold design for micro injection molding are as below:
Except that the size of the micro-injection mold is obviously smaller than that of the traditional mold,
It also has the following characteristics:

Due to the small size, the number of cavities is reduced, which is beneficial to improve the balance of the mold and improve the accuracy of the product appearance size.

Due to the small size, it is easier to control the stability of mold temperature, in line with the requirements of precision forming, and also saves the energy required by mold heating/cooling:

Hot runner system is generally recommended to use: Because of the low mold cost, and the short development cycle.

5.What processing methods can be used for micro injection molding mold?

The processing methods that can be used for micro injection molding mold are as below:
The following processing methods can be used for micro injection molding tools:
Such as various machining methods and electrical discharge machining (EDM),
However, with the decrease of mold insert and cavity size, the traditional methods quickly reach their processing limit.
At present, some technologies in the field of microelectronics have been used in the manufacturing of micro-injection mold inserts and cavities.
One common method is LIGA, which is a German acronym for 2-1 deep ray lithography, electroplating, and injection molding replication.
Other processes include micro-cutting, ultra-precision machining, laser machining, and micro-EDM technology.

6.Which equipment is essential for the correct production and collection of micro injection molded products?

Improved mold sensor, high precision mold guide device, mold extraction system, integrated channel collector and manipulator for product removal, automatic gate removal system,
And the mold cleaning system activated in each cycle.

7.What plastic materials can be used for micro injection molding?

Micro injection molding materials include Polyformaldehyde (Pom), polycarbonate (PC), Poly(methyl methacrylate), nylon (PA), Liquid Crystal Polymer, polyetherimide (Pei), and silicone rubber. Acrylic, acrylamide, and siloxane-based materials have also been used for reactive injection.

Most common engineering plastics are suitable for micro injection molding.
After comparing PP, PA, and POM materials, it is concluded that PP is the most suitable material for forming micro-gears.

After comparing the microinjection medical needles of PS, PA6-nanomaterials, PC, and other materials, it was concluded that the products injected with PA6-nanomaterials were of poor quality, which may be due to the material’s high moisture absorption.

8.What are the advantages of micro injection molding?

Micro injection molding is an important process of thermoplastic molding.
It can reduce the manufacturing cost, shorten the production cycle,
the forming process is simple, easy to ensure the quality of components,
easy to realize automation and batch production.
Micro-injection molding technology has become one of the key technologies in micro-manufacturing. It is developing rapidly.

1)Based on the traditional injection molding technology, with very mature technical experience and versatility;
2)Standardized process operation procedures reduce the difficulty of injection molding.
3) Highly automated pipelining processes to reduce the destabilizing effects of human factors;
4)Ultrashort production molding cycle, conducive to rapid and stable production requirements.

 

9.What are the main disadvantages of the Micro Injection Molding Process?

The main technological disadvantages of micro injection molding are as follows:
With the large volume of the flow passage, Sometimes the material in the runner may account for 90% of the total injection weight,
For micro injection products, Most of the material in the runner is not recyclable,
Material waste a lot.

10.What are the special molding processes in micro injection molding?

1) Mold temperature
The mold temperature in the micro injection is generally higher than the glass transition temperature of the forming material to obtain the well-filled products.

When the mold temperature is lower than or only a little higher than the glass transition temperature of the material, the increase of the die temperature has no good effect on the improvement of product quality.

2)Injection speed
The injection speed directly affects the quality of the micro injection parts.

The uniform filling effect can be obtained at a high injection speed

Reduce the stress inside the micro ware.

3)Melt temperature

The three most important parameters affecting the quality of the product are melt temperature, holding pressure, and holding time.

When the melt temperature increases, the viscosity of the melt decreases, which is conducive to plastic melt mold filling.

When the melt temperature increases, the viscosity of the melt decreases, which is conducive to plastic melt mold filling.

When the melt temperature remains high, the dimensional precision of the molded product is higher.

Melt temperature is an important factor affecting micro injection products except for mold temperature and injection speed.

 

11.What are the mold design considerations for micro injection molding?

1)Design of variable temperature mold.

In the process of micro injection molding, Because the mold cavity surface area and volume is relatively large.
As a result, melt temperature varies widely in the filling stage,which seriously affects the molding quality and molding cycle of the products.
Therefore, micro injection mold usually needs to design the mold temperature changing system.
At present, the mold temperature change system mainly includes an induction heating mold temperature change system, an electric heating water cooling mold temperature change system, and so on.
For example, the high-frequency induction heating modulating temperature system designed by YAO at Georgia Institute of Technology, It can increase the cavity temperature from room temperature to 240℃ within 5s, greatly shortening the molding cycle.

2)Design of vacuum exhaust system
Because of the high machining precision of the surface of the micro-mold,
when the mold is closed, the gap between the moving mold and the fixed mold is very small,
and the residual air and the gas released from the melt in the mold cavity are difficult to be discharged from the mold cavity gap, which affects the molding quality and the melt filling rate of the products, the vacuum exhaust system is usually designed for the micro tool.
At present, the method of vacuum exhaust is mainly by sealing around the
cavity, opening an exhaust passage on the parting surface and then using a vacuum pump to extract the gas from the cavity.

3)Design of demoulding mechanism

In view of the characteristics of lightweight, thin wall and low strength, the traditional demulsifying mechanism is easy to deform the microstructure and even damage it, which seriously affects the forming quality of the product.
In order to make the product demoulding smoothly and ensure its forming quality, the micro injection mold needs to design a demoulding mode suitable for the structural characteristics of the micro products.
According to the structural characteristics of different micro products, researchers adopt different demoulding design mechanisms.

 

12.What is the difficulty of micro injection mold manufacturing?

The micro cavity is the core part of the micro injection molding mold. Its structure size and accuracy are at the micron level. Its structure size and precision at the micron level.
High surface accuracy is required.
They are the difficult point to manufacture micro injection mold.

13.What technologies are currently used for the processing of micro-cavities manufacture?

At present, micro-machining technology, micro-special machining technology, and LIGA-based machining technology are mainly used for micro-cavity manufacture.

14.What are the micro special machining techniques used to process the cavity of the micro injection mold?

The Micro Special Machining Technology for Micro injection molding mold cavity mainly includes micro Electrical discharge machining, Micro Electro chemical Machining, Micro electroforming, and so on. The machining precision is generally within 100nm.

15.What are the control methods of micro injection mold temperature?

1)Mold temperature variation system designed by Germany IKV:
The external device keeps the temperature of the whole mold constant. The internal device consists of a disassembled tubing and an electric heater, The local surface of the mold cavity can be heated.

2)Infrared rapid heating system: The heating system has the advantage of low cost, strong practicability, and can improve the forming quality obviously.

Gas flame heating method: Heating efficiency is related to mold surface roughness

Electromagnetic induction heating with water cooling method: It can control the temperature of the local area of the microplastic mold, obtain a more uniform temperature distribution, and obtain high-quality microstructural products.

16. What is the range of application of Micro Injection Molding?

1)Micro-products: micro-products, such as micro-gears, micro-joysticks, and so on, weighing micrograms or one-tenth of a Gram in size of mm or less;

2)Micro Tolerance products: arbitrary size, but the size of the tolerance required to measure the scope of the micron-level high-precision products, such as fiber connection.

3)Products with micro structural-functional features: products with special structural requirements, such as optical discs with data point gaps, lenses with micro-surface features.

17. What are the equipment requirements for micro-injection molding?

1)Micro-plasticizer, using short screw whose L/D ratio is about 15 and whose screw diameter is in the range of 12-18mm, in order to avoid the risk of degradation of raw materials;

2)High Precision injection volume control system to achieve the most reasonable and accurate control of injection volume;

3)Ideal injection speed control system to ensure that the injection molding process can be completely and perfectly communicated;

4)Precise mold temperature control is beneficial to ensure the forming quality of the melt in each part of the complex structure

4)The mold has vacuum function, which has a more accurate dimension stabilization function and injection assistant function for micro-products

6) Self-sealing nozzle to avoid salivation and injection volume instability;

7)Precise and flexible mold closing system to protect the precision mold and injection molding conditions from changing;

8)Repeatable processes that allow you to produce tasks quickly and repeatedly.

18.What are the key points of micro-injection molding process?

1) Microinjection molding requires high-speed injection capacity, high injection pressure, high melt temperature within the allowed range, and mold wall temperature needs accurate control, all of which are necessary.

2) Large flow passage and large gate design should be used in the mold development so that the melt can have a more reliable flow passage and switching ability in the mold cavity.

3) Perfect auxiliary equipment: it is very important to use a high-precision mold guiding device, mold extraction system, channel collector and product removal mechanism, automatic gate removal system and automatic activation mold cleaning system, and even effective product packaging treatment system.

19. What are the advantages of micro-injection molding?

Advantages: Due to the particularity of target products of micro injection products,
there is no competitive relationship between the micro injection molding process and the traditional injection molding process.
And the characteristics of the two injection molding processes are very similar, Process characteristics and problem solutions are the same, so the technical difficulty of micro
injection molding can be solved instantaneously.

 

20. What are the disadvantages of micro injection molding?

Disadvantages: small products and large flow passage, flow port material point ratio up to more than 90%, serious waste of materials; Because of the higher mold temperature and melting temperature used, The solidification period becomes longer and the energy consumption increases.

At this point, we have a relatively comprehensive understanding of the micro injection molding process. The interconnectivity of micro injection molding and traditional molding technology greatly improves their usability. And has the innate advantage in the craft problem to solve. As long as grasp the key points of equipment and process, you can quickly carry out the production task.

21.What are the challenges of micro injection molding?

Most micro products begin with some degree of Extreme Challenge.
They are usually smaller versions of similar products on the market.
Tiny components become more complex because they need to be mounted in tiny, delicate arteries, pumps, catheters, or endoscopes, and there may be tiny components inside that need to work.
They are often challenging geometries because they were once designed as two or more components,
but were reduced to one because of cost pressures so that they would not have to be assembled under a microscope.

These devices may require drugs that are directly combined with or added to a polymer, metal, or membrane.
And with working gears, levers, and driving mechanisms, In order to make the device work repeatedly and have a reliable life.
Consider these features,And the requirement that these devices can be implanted directly into the human body.
It is important to develop these devices in a robust manner and to test their shape, fit, and function well.

22.What are the considerations for Mold Components in micro injection molding?

Flow Channel
In automated assembly operations, it can be used as a handle to hold the part in place, or special locating points can be added to the runner to help us locate the workpiece in the assembly nesting.

Parting line
The parting line of micro injection mold is related to the size of micro parts.
A difference of 10 microns on the parting line can easily disrupt the assembly of the product.

Demoulding slope
The more taper you can get, the better it will be. but it can be as small as 0.2 degree taper.
This kind of taper for injection molding parts, processing will be very troublesome.
Placing a miniature part on a taper creates an irregular surface that affects assembly

Gate position
As with ordinary injection molds, the micro injection molds are also selected with the gate position to ensure a uniform flow of plastic in the cavity. Otherwise, the spare parts may not be fully filled and may damage the precision pin and cavity parts in the mold.

Gate residue
Edge sprue is used for most micro – molded parts, they need to remove the gate properly,
To avoid problems with small materials causing arterial damage (implant equipment) or causing auto-actuation and assembly problems In-mold design, these problems can be solved by placing a pit in the wall thickness. The sprue residue will be designed below the surface of the guide or mating part of the assembly.