Overview

Engineered for medical device OEMs, electronics manufacturers, and automotive Tier-1 suppliers, micro precision injection molded parts are specialized thermoplastic components designed for miniature assemblies where standard molding tolerances fail. Utilizing electric micro-molding presses and ultra-small barrel diameters, these components feature sub-gram shot weights, thin walls down to 0.12 mm (under high-precision conditions), and tight tolerances ±0.005 mm. Manufactured in controlled environments adhering to ISO Class 7/8 cleanroom standards and supported by ISO 13485 and IATF 16949 quality systems, they serve critical functions in high-reliability sectors where space constraints, contamination control, and dimensional stability dictate performance.

Specifications

Parameter	Standard Capability	High-Precision Capability
Shot Weight	0.05 g - 5.0 g	< 0.01 g (Micro-shot)
Dimensional Tolerance	±0.01 mm	±0.005 mm
Min. Wall Thickness	0.15 mm*	0.12 mm
Hole Diameter	≥ 0.10 mm	≥ 0.05 mm
Cavitation	1 to 64 Cavities	Single to 32 Micro-cavities (Hot runner/valve gate)
Clamping Force	15 Tons	5 Tons - 30 Tons (All-electric)

Features

Zero-Flash Gate Removal: Automated de-gating and micro-machined parting lines eliminate manual trimming burrs on functional edges.

Stable Micro-Shot Control: Dedicated low-volume screw barrels prevent polymer residence time degradation and thermal shear.

High Aspect Ratios: Capable of molding deep, narrow ribs and thin-walled micro-tubes without short shots or warping.

Traceability: Laser-etched cavity IDs on tools ensure strict lot tracking from pellet to packaged part.

Materials & Manufacturing

Supported Resins
Medical / FDA Grades: PEEK, PSU, PPSU, PEI (Ultem), LCP, and medical-grade Polycarbonate.

High-Performance Engineering Plastics: POM (Delrin), PA66, PVDF, PTFE-filled blends, and TPU.

Manufacturing Process
Production utilizes dedicated all-electric micro-injection molding machines equipped with high-response servo-driven injection screws inside controlled environments. Tooling is manufactured via high-speed CNC milling, wire EDM, and micro-sinker EDM, paired with optical profile grinding. Mold inserts are matched with hardened tool steels (e.g., S136, BeCu for thermal management) to sustain high cycle pressures without deflection.

Applications

Medical Technology: Catheter components, surgical stapler gears, micro-fluidic diagnostic chips, and hearing aid shells.

Electronics & Telecom: Fiber optic connectors (ferrules, sleeves), micro-switch housings, and sensor spacers.

Automotive: Miniature actuator gears, fuel system check valves, and dashboard sensor clips.

Customization

DFM Iteration: Engineering review of draft angles, gate locations, and shrink rates prior to tool cutting.

Secondary Operations: Cleanroom assembly, ultrasonic welding, laser marking, and custom carrier-tape packaging.

Prototyping: Rapid tooling inserts for functional sample generation within 10–15 business days.

QC & Inspection

Optical Measurement: Keyence IM-8000 image dimension measurement system and high-resolution optical comparators.

3D Scanning: Micro-CT scanning for internal void analysis and non-destructive wall thickness verification.

In-Line Monitoring: Closed-loop machine monitoring tracking cavity pressure, injection velocity, and melt temperature per shot.

FAQ

Q: What is the minimum wall thickness you can mold reliably?

A: We routinely mold walls down to 0.15 mm, and down to 0.12 mm under high-precision conditions, depending on the resin's melt flow index (MFI) and flow length.

Q: How do you handle micro-tooling wear and dimensional drift?

A: We use certified high-grade tool steels combined with rigid machine repeatability (±0.01 mm position accuracy) and strict first-article inspection (FAI) protocols.

Q: Can you assist with material selection for biocompatible applications?

A: Yes. We supply FDA-compliant and USP Class VI certified engineering resins and provide material certificate data sheets (MTRs) with every shipment.