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Precision Injection Moulding
Accuracy and Reproducibility for Precise Components
Shape accuracy, surface quality, part weight or microstructure - precision injection moulding has many aspects. Plastic parts are penetrating new areas of application and the requirements are becoming ever higher. Thanks to suitable plasticising and software solutions as well as injection moulding processes, you can raise precision injection moulding to a new level.
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Reproducible components thanks to optimum machine design
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High melt quality as a prerequisite for precision injection moulding
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Constant component weight with digital assistance software
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High-quality surfaces thanks to multi-layer injection moulding
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Flawless microstructure thanks to system for smallest shot weights
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Surface details thanks to heating and cooling in each cycle
The general basis for precision injection moulding is the optimal design of the injection moulding machine. To ensure the reproducibility of shot weights, precise plasticising 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 repeatability and process control in the production of precision parts.
Precision in injection moulding at ENGEL includes optimised plasticising processes to reduce or completely eliminate internal component defects. The optimelt sequence programme enables significant improvements in this area. The software-based solution provides the user with a flexible modular system for the plasticising sequence. It enables, for example, additional melt compression steps, thus improving the plasticising process.
The digital solution iQ weight control optimises the injection volume during the ongoing injection moulding process. This compensates for fluctuations in the melt viscosity. iQ weight control reacts to external influencing factors. The software ensures that the accuracy of the injection moulding process is increased, and the component weight remains constant despite viscosity fluctuations. For moulds with multiple cavities, iQ weight control helps you to minimise rejects due to overinjection or mould cavities that are not completely filled.
With multi-layer technology, you achieve an exact reproduction of the mould surface for your precision injection moulded components. It is mainly used to produce thick-walled lenses. The base body is pre-moulded on the first machine, which is then over-moulded on a second machine. The high accuracy of the finished part is defined during overmoulding. The surface quality is ensured independently of shrinkage influences. You achieve higher dimensional accuracy and advantageous optical properties.
The most prominent example of precision requirements is micro injection moulding. Part weights of a few thousandths of a gram and correspondingly fine structures can only be achieved through high-precision machine movements. Our injection unit closes the gap for micro components and allows shot weights in the range of 0.3 grams. Thanks to its precise design, the smallest microstructures for your components can be produced without errors.
Variotherm processes are well suited to avoid large-area or localised marking of weld lines. They are used for high-gloss effects on surfaces and ensure the complete filling of mould cavities. The processes are based on pressurised water or heat transfer oils and allow hot-cold switching of mould areas. They improve the detail accuracy of components in precision injection moulding. Other variotherm processes are based on inductive heating solutions or the partial use of heating elements.
The general basis for precision injection moulding is the optimal design of the injection moulding machine. To ensure the reproducibility of shot weights, precise plasticising 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 repeatability and process control in the production of precision parts.
Precision in injection moulding at ENGEL includes optimised plasticising processes to reduce or completely eliminate internal component defects. The optimelt sequence programme enables significant improvements in this area. The software-based solution provides the user with a flexible modular system for the plasticising sequence. It enables, for example, additional melt compression steps, thus improving the plasticising process.
The digital solution iQ weight control optimises the injection volume during the ongoing injection moulding process. This compensates for fluctuations in the melt viscosity. iQ weight control reacts to external influencing factors. The software ensures that the accuracy of the injection moulding process is increased, and the component weight remains constant despite viscosity fluctuations. For moulds with multiple cavities, iQ weight control helps you to minimise rejects due to overinjection or mould cavities that are not completely filled.
With multi-layer technology, you achieve an exact reproduction of the mould surface for your precision injection moulded components. It is mainly used to produce thick-walled lenses. The base body is pre-moulded on the first machine, which is then over-moulded on a second machine. The high accuracy of the finished part is defined during overmoulding. The surface quality is ensured independently of shrinkage influences. You achieve higher dimensional accuracy and advantageous optical properties.
The most prominent example of precision requirements is micro injection moulding. Part weights of a few thousandths of a gram and correspondingly fine structures can only be achieved through high-precision machine movements. Our injection unit closes the gap for micro components and allows shot weights in the range of 0.3 grams. Thanks to its precise design, the smallest microstructures for your components can be produced without errors.
Variotherm processes are well suited to avoid large-area or localised marking of weld lines. They are used for high-gloss effects on surfaces and ensure the complete filling of mould cavities. The processes are based on pressurised water or heat transfer oils and allow hot-cold switching of mould areas. They improve the detail accuracy of components in precision injection moulding. Other variotherm processes are based on inductive heating solutions or the partial use of heating elements.
We support you with solutions for a constant part weight and fully formed surfaces. Even for the smallest components.
| Procedure | Product name | Industry | Application | Process |
|---|---|---|---|---|
| Silicone Processing / Liquid Injection Moulding | LIM | Various | Primary optics LED headlamp | Processing of materials that only cross-link in the mould |
| Processing transparent materials | optimelt | Automobile & Mobility Electronics | Light guides, lenses in smartphone cameras | Transparent components for optical applications |
| Production of thick-walled lenses | optimelt Multi-Layer | Automobile & Mobility | Secondary optics LED headlights | Transparent components for optical applications |
| Hot-cold switchover | Variotherm technology | Automobile & Mobility Electronics | Achieving a high gloss surface through alternating mould temperature control |
Optical components place high demands on internal freedom from defects during injection moulding. The cause of small defects are gases that get into the melt. We use a software to reduce the entrapment of gases resulting in an increase in the melt quality.
Präzisionsspritzguss für die kleinsten Bauteile. Flüssig-Silikon flexibel und präzise verarbeiten, selbst bei Mehrkomponenten-Anwendungen. Vollautomatisch in einem Arbeitsschritt nacharbeits- und abfallfrei.
Our micro injection moulding unit can be installed on a standard machine from the e-motion TL series within 20 minutes. This means that the unit can be converted for micro injection moulding.
The fully electric injection unit is controlled by servo motors. It is characterised by dynamic acceleration, high positioning accuracy and reproducibility as well as universal applicability.
The micro injection unit is integrated into the machine control and has a maximum injection pressure of approx. 1000 bar. The injection pressure regulation is controlled via melt pressure sensors in the nozzle.
Precision and ergonomics
Low-flash, rework- and waste-free products
Transparent components made of PMMA, PC or COC for optical applications. With the injection moulding process for optical plastic products such as light guides or lenses, you can produce moulded parts that meet your requirements for contour accuracy. For optical applications, it is important that the melt is processed gently, and the plasticising components have optimum self-cleaning properties. Otherwise, material degradation could occur during plasticising or in stagnation areas. This would result in defects that would be visible on the final component. ENGEL therefore offers special plasticising components for transparent materials.
Suitable for a variety of demanding applications in the field of camera and lighting optics.
Precise injection-compression moulding of lenses and optical components.
Variotherm mould temperature control for finest structures and increased accuracy.Variotherme Werkzeugtemperierung für feinste Strukturen und erhöhte Genauigkeit.
Plastic parts are produced layer by layer. The multi-layer working method ensures accelerated cooling through layer build-up and high contour accuracy as well as shortened cycle times.
Precision injection moulding with high efficiency
Contour accuracy
Consistent part weight
More uniform shrinkage
Process for Thick-Walled Precision Injection Moulded Parts
Concept with two machines to produce multi-layer lenses. The pre-moulded parts cool in the air between the first and the second machine.
 "Process for Thick-Walled Precision Injection Moulded Parts")
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 "Johannes Kilian | ENGEL")
Precision injection moulding is not only defined by the size of a component. It is often the details on the components that demand the highest accuracy from our machines. ENGEL takes on this task in all customer projects and offers customised solutions for every area.
Liquid Injection Moulding - an injection moulding process for the production of elastic moulded parts from 2-component liquid silicone rubber
Poly (methyl methacrylate), a transparent, thermoplastic material
Polycarbonate, a thermoplastic material.
Cyclo-olefin copolymer, engineering polymers.
Liquid Silicone Rubber, soft liquid silicone.
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 structures. The prerequisite is the geometric feasibility as well as the compatibility of the individual layers.
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