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Precision Injection Molding of Plastic Parts
Accuracy and Reproducibility for Precise Parts
Shape accuracy, surface quality, component weight, or microstructure: precision injection molding has many faces. Plastic parts are entering new areas of application and the requirements are becoming ever more stringent. Suitable plasticizing and software solutions, as well as injection molding processes, let you elevate precision injection molding to a new level.
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Reproducible production thanks to optimum machine design
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High melt quality as a prerequisite for precision injection molding
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Consistent part weight with digital assistance software
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High-quality surfaces thanks to multi-layer injection molding
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Error-free microstructure for lowest shot weights
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Surface details through heating and cooling in each cycle
The basis for precision injection molding is the ideal design of the injection molding machine. To ensure the reproducibility of shot weights, precise plasticizing components such as non-return valves with smart-shut technology are used. In combination with electric injection units, the non-return valve meets your requirements for reproducibility and process control in the production of precision parts.
At ENGEL, precision in injection molding includes optimized plasticizing processes to reduce or completely eliminate internal part defects. The optimelt sequence program enables significant improvements in this area. The software-supported solution provides the user with a flexible modular system for the plasticizing sequence. It allows, for example, additional melt compression steps, therefore improving the plasticizing process.
The digital solution iQ weight control optimizes the injection volume during the injection molding process. This compensates for fluctuations in melt viscosity. iQ weight control reacts to external influences. The software ensures that the accuracy of the injection molding process is increased, and the part weight remains constant despite viscosity fluctuations. For molds with multiple cavities, iQ weight control is the right choice. It minimizes scrap due to overfilled or incompletely filled mold cavities.
With multi-layer technology, you can achieve an exact reproduction of the mold surface of your precision injection molded parts. It is mainly used to produce thick-walled lenses. The substrate is molded on the first machine, which is then overmolded on a second machine. The high precision of the finished part is defined during overmolding. Surface quality is guaranteed regardless of shrinkage. You achieve higher dimensional accuracy and beneficial optical properties.
The most striking example of precision requirements is micro injection molding. Part weights of a few thousandths of a gram and fine structures can only be achieved by high-precision machine movements. Our injection unit fills the gap for micro components and enables shot weights in the 0.3 gram range. Thanks to its precise design, the smallest microstructures for your parts can be produced without defects.
Variotherm processes are well suited to avoiding larger or smaller weld lines. They are used for high-gloss effects on surfaces and ensure complete filling of mold cavities. The processes are based on pressurized water or heat transfer oils and allow hot-cold switching of mold areas. They improve the detail accuracy of parts in precision injection molding. Other variotherm processes are based on inductive heating solutions or the partial use of heating elements.
The basis for precision injection molding is the ideal design of the injection molding machine. To ensure the reproducibility of shot weights, precise plasticizing components such as non-return valves with smart-shut technology are used. In combination with electric injection units, the non-return valve meets your requirements for reproducibility and process control in the production of precision parts.
At ENGEL, precision in injection molding includes optimized plasticizing processes to reduce or completely eliminate internal part defects. The optimelt sequence program enables significant improvements in this area. The software-supported solution provides the user with a flexible modular system for the plasticizing sequence. It allows, for example, additional melt compression steps, therefore improving the plasticizing process.
The digital solution iQ weight control optimizes the injection volume during the injection molding process. This compensates for fluctuations in melt viscosity. iQ weight control reacts to external influences. The software ensures that the accuracy of the injection molding process is increased, and the part weight remains constant despite viscosity fluctuations. For molds with multiple cavities, iQ weight control is the right choice. It minimizes scrap due to overfilled or incompletely filled mold cavities.
With multi-layer technology, you can achieve an exact reproduction of the mold surface of your precision injection molded parts. It is mainly used to produce thick-walled lenses. The substrate is molded on the first machine, which is then overmolded on a second machine. The high precision of the finished part is defined during overmolding. Surface quality is guaranteed regardless of shrinkage. You achieve higher dimensional accuracy and beneficial optical properties.
The most striking example of precision requirements is micro injection molding. Part weights of a few thousandths of a gram and fine structures can only be achieved by high-precision machine movements. Our injection unit fills the gap for micro components and enables shot weights in the 0.3 gram range. Thanks to its precise design, the smallest microstructures for your parts can be produced without defects.
Variotherm processes are well suited to avoiding larger or smaller weld lines. They are used for high-gloss effects on surfaces and ensure complete filling of mold cavities. The processes are based on pressurized water or heat transfer oils and allow hot-cold switching of mold areas. They improve the detail accuracy of parts in precision injection molding. Other variotherm processes are based on inductive heating solutions or the partial use of heating elements.
We support you with solutions for consistent part weight and fully formed surfaces – even for the smallest components.
| Process | Product name | Industry | Application | Procedure |
|---|---|---|---|---|
| Silicone processing / liquid injection molding | LIM | Various | Primary optics LED headlights | Processing of materials that crosslink only in the mold |
| Processing transparent materials | optimelt | Automotive & mobility Electronics | Fiber optics, lenses of smartphone cameras | Transparent components for optical applications |
| Thick walled lens production | optimelt multi-layer | Automotive & mobility | Secondary optics LED headlights | Transparent components for optical applications |
| Hot-cold switchover | variotherm technology | Automotive & mobility Electronics | Achieving a high-gloss surface through alternating mold temperature control |
For optical parts, avoiding internal defects during injection molding is extremely important. Small defects are the result of gases that get into the melt. We reduce the ingress of gases with software. The melt quality is increased.
Precision injection molding for the smallest parts. Flexible and precise processing of liquid silicone, even for multi-component applications. Fully automated in a single step, no reworking necessary, and waste-free.
Our micro injection molding unit can be installed on a standard machine of the e-motion TL series within 20 minutes. Which means the machine can be converted for micro injection molding.
The all-electric injection unit is controlled by servo-motors. It features dynamic acceleration, high positioning accuracy, and reproducibility, and can be used in a variety of applications.
The micro injection unit is integrated into the machine control unit and has a maximum injection pressure of approximately 1000 bar. The injection pressure regulation is controlled via melt pressure sensors in the nozzle.
Precision and ergonomics
Low burr, no rework necessary and waste-free parts
Transparent parts made of PMMA, PC or COC for optical applications. With the injection molding process for optical plastic products such as light guides or lenses, you produce molded parts that meet your requirements for outline accuracy. For optical applications, gentle processing of the melt and optimum self-cleaning behavior of the plasticizing components are important. Otherwise, material degradation could occur during plasticizing or in stagnation areas. This would result in defects that would be visible on the final part. ENGEL therefore offers special plasticizing components for transparent materials.
Suitable for a variety of demanding camera and lighting optics applications.
Precise injection compression molding of lenses and optical components.
Variotherm mold temperature control for best structure replication and increased accuracy.
Plastic parts are manufactured layer by layer. The multi-layer method ensures accelerated cooling through layer build-up and high outline accuracy as well as shorter cycle times.
Highly efficient precision injection molding
Outline accuracy
Consistent component weight
More uniform shrinkage
Process for Thick-Walled Precision Injection Molded Parts
Process with two machines to produce multilayer lenses. The molded parts cool in air between the first and the second machine.
 "Process for Thick-Walled Precision Injection Molded Parts")
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Precision injection molding is not only defined by the size of a component. Often the details on the parts demand the highest accuracy from our machines. ENGEL accepts this challenge for all customer projects and offers customized solutions for every application.
Liquid Injection Molding - an injection molding process for producing elastic molded parts of two-component liquid silicone rubber
Polymethyl methacrylate, a transparent thermoplastic material
Polycarbonate, a thermoplastic material
Cyclo-olefin copolymer, engineering polymers
Liquid silicone rubber, soft liquid siliconeLiquid Silicone Rubber, weiches Flüssigsilikon.
Although the technology was developed specifically for lens technology, it is not only applicable to transparent plastics. The process can be used for any thick-walled components. The prerequisite is geometric feasibility and compatibility of the individual layers.
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