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Solutions/Plastic Injection Molding/Micro Molding

Micro Molding Services

High-quality micro molding for parts with intricate geometries and excellent surface finishes. Subject to availability.

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ISO 9001

ISO 13485

AS9100D

FDA / Medical

What is Micro Molding?

Micro molding is a highly advanced, specialized manufacturing process for complex, miniature parts with high precision. A subset of plastic injection molding, it is tailored for parts with features typically less than one millimeter. It is used in medical device manufacturing, electronics, automotive, and aerospace. Advantages include efficient production of precise parts with minute features in large volumes and a wide range of materials.

We offer high-quality micro molding services for a variety of industries. Common applications include integrated circuit components and automotive door-locking mechanisms. Our manufacturing network and experience ensure high quality and short lead times.

The Micro Injection Molding Process

The process is nearly identical to standard plastic injection molding but requires more careful control. Molds and die sets are fabricated using EDM, micro EDM, and micro-machining for tolerances as small as a few micrometers. Thermoplastic or liquid silicone rubber is melted, forced into the micro mold at a controlled flow rate, held under pressure while cooling, then ejected and inspected. Advanced machine controls keep parameters stable and consistent.

Types of Micro Molding

Insert Molding

A metal insert is placed in the mold (manually or by robot); plastic is injected in a single shot around it. Used for catheters, micro-optic and IC components.

Overmolding

Substrate is injected first, then a second material or color is layered on top for multi-material or multi-color parts. Used for multi-color buttons, housings, seals, gaskets.

Material Selection for Micro Molding

Thermoplastic polymers and specialized resins must be vetted for suitability, especially in medical applications.

Polyethylene (PE)

FDA-compliant; chemical and thermal resistance, high tensile strength. Packaging, consumer goods, textiles.

Polypropylene (PP)

Rigidity, wide temperature range, chemical and fatigue resistance. Packaging, machinery, textiles, consumer goods.

Nylon (Polyamide)

Chemical resistance, strength, dimensional stability. Textiles, electrical housings, bearings, bushings, sprockets.

Polycarbonate (PC)

Transparency, optical clarity, impact strength, chemical and fire resistance. Electrical housings, switches, machine guards.

Delrin® (POM / Acetal)

Strength, toughness, rigidity, chemical and flame resistance, low friction. Gears, pulleys, rollers.

Polysulfone (PSU)

Translucent, biocompatible, food compatible, wide temperature range. Food prep and medical.

PBT

Dimensional stability, strength, chemical/UV/thermal resistance, low moisture absorption. Automotive, electronics, power-tool housings.

Acrylic (PMMA)

Optical clarity, tensile and impact strength, light weight. Signage, windows, machine guards.

PEEK

Wide temperature range (up to 250°C), strength, chemical resistance, stiffness. Bushings, seals, valves, electrical housings.

ULTEM® (PEI)

Rigidity, mechanical strength, creep resistance. Electrical insulator; coils, fuses, aircraft interior trim.

LCP (Liquid Crystal Polymer)

Ordered microstructure; mechanical strength, temperature and flame resistance. Connectors, catheters, surgical instruments, cookware coatings.

Micro Molding Advantages

Lightweight

Creates small, lightweight parts—ideal for medical implants, small electronics, microfluidic components.

Size

Exceptionally small parts. Micro-machining and EDM create precise cavities; parts fit confined spaces. Electronics, medical implants, micro-optics.

Less Energy and Time

Smaller tools and machinery, smaller clamping forces, shorter cycle times. Significant cost savings vs conventional injection molding.

Tight Tolerances

Tolerances as small as 0.005" to 0.015". Micro-machining and EDM for accurate cavities and cores. Electronics, medical, micro-optics.

Chemical Resistance

Thermoplastics offer great chemical resistance for corrosive environments. Medical implants, instruments, valves, consumer and electronics.

Micro Molding Applications

Medical Devices

Implants
Catheters
Drug delivery systems
Diagnostic equipment

Common materials: PE, PP, PC

Drones

Housings, switches, connectors for optical equipment
Actuators and gears
Sensor housings
Structural components

Common materials: PC, acetal, acrylic, PEI, nylon

Surveillance Equipment

Lenses
Mirrors
Plugs
Switches

Common materials: PE, PP, acrylic

Fitness Trackers

Switches
Housings
Plugs

Common materials: Nylon, acrylic, PC

Robotics

Sensor housings
Switches and connectors
Gears and actuators

Common materials: Acetal, PP, PC, PE, acrylic

Automotive

Brake pad components
Fasteners, washers, clips
Door locking mechanisms
Switches
Micro gears
Buttons

Common materials: Various

Other Features

Surface Finish

Micro-machining and EDM attain precise dimensions and desirable mold textures for smooth, finished parts.

FDA Registered

ISO 13485 certified; micro molded parts fabricated to regulatory standards for medical use.

High-Volume Production

Multi-cavity molds; 30–60 second cycle times; hundreds to thousands of parts per day.

Drug Delivery Devices

Microneedle patches, small robotic pills, and other devices for administering medicines; micro molding enables fabrication.

Alternatives to Micro Molding

3D Printing

Can produce tiny plastic or metal parts with complex features layer-by-layer. SLA, DLP, SLS, SLM can achieve dimensions as small as +0.010". Often more expensive due to equipment and slower processing.

Micro-Machining

Micro CNC milling or µEDM. Micro milling: tolerances as low as 0.001"; µEDM: 0.008" or 0.02 mm. Similar tolerances to micro molding but often more expensive due to machine cost and slower process.

3D Printing →Micro Machining →