Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

Micro-injection molding requires highest precision in all phases of the injection molding process, including consistency of shot weight. One ongoing commercial molding program involves connectors made of liquid crystalline polymer (LCP) with a shot weight of 0.484 g and an injection time of 0.018 sec. The Engel customer is achieving great results here thanks to the “smart-shut” sliding-ring nonreturn valve: The deviation per shot is a maximum of +/-0.0005 g, which is about 0.1%.

For the market launch of the micro-injection unit at the end of 2020, it was used to mold connecting elements for medical instruments in a valve-gated, cold-runner mold with 32 cavities. The delicate parts measure 1.7 mm long × 0.9 mm diam., with a combined part weight of just 16 mg. The unit runs on an all-electric and tiebarless Engel e-motion 50/30 TL injection molding machine and is supplied by an LSR metering pump from ACH Solution. An Engel viper 6 linear robot removes the parts and deposits them on a conveyor belt for camera-based quality control.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

A new LSR micro-injection unit, developed jointly by Engel and ACH Solution (both in Austria), makes it possible to manufacture precision parts from LSR with shot weights significantly below 0.1 g. The unit consists of a plunger rather than a screw; but ACH incorporates a dynamic mixer (rather than a more typical static mixer) into the feed system to ensure a good mix of the silicone A and B components and pigment, if any. Technically, it may be considered a two-stage injection system, because there is a hold stage for the mixed liquid components, followed by an injection stage. Plunger diameter is 6 mm and maximum shot capacity is 2.26 cm3. For very tiny components, Engel recommends using this system together with its iQ weight control software.

Maximum precision in the interaction of all units of the system is indispensable here. Engel recommends for this purpose all-electric and tiebarless injection molding machines from its e-motion TL series, not only for development, lab work and prototyping or for short runs, but also for high-volume production (Fig. 2). These precision machines are complemented by a new flexible micro-injection unit (see sidebar) that was developed as a dedicated solution for LSR micro-injection molding.

Another feature of this system is a barrel-coding option that permits replacing the ACH micro-injection unit with a standard screw plasticating unit for LSR or thermoplastic. For processing LSR on the conventional screw with an ACH metering pump, the barrel-coding software disables screw rotation so that it functions just as a plunger, and adjusts the injection pressures and volumes for the barrel diameter.

FIG. 3 The automotive industry is one of the main drivers of the micro trend. This air-intake valve for the massage function in vehicle seats measures 4 × 3 mm and combines LSR and nylon in an overmolding application. (Photo: Sei Woo)

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

Some special features must also be taken into account in handling the tiny parts, the automation on the machine, and quality control. Takeoff by means of a gripper is just as unthinkable as allowing sensitive parts to simply drop off the mold.

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Micro-injection processes might have worked well under laboratory conditions, but during scale-up and high-volume production, the molders and equipment suppliers face completely new challenges. This applies above all to the dimensional accuracy of the parts. Factors that have virtually no effect on large parts are decisive for the reject rate in the case of delicate micro-parts. Deviations of a few thousandths of a millimeter or a few tenths of a milligram have a major impact on the quality of these tiny parts, and thus on their subsequent reliability in use.

The LSR microparts are still very hot on demolding, which must be taken into account when designing the automation system for parts handling. Particular attention must be paid to using heat-resistant materials and measuring technology here.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

Raw-material supply to the injection molding machine is another point where LSR and thermoplastic micro-injection molding differ. The two components of liquid silicone are stored in containers whose volume should not exceed 0.5 to 0.7 liters for microinjection molding. To additionally protect the material, the hose connections to the barrel also should be as short as possible and have only a narrow cross-section. When selecting the metering pumps for the molding system, Engel gives priority to working with partners whose units are OPC UA-capable in order to ensure integration into the machine control system.

Better control of LSR mixing/dosing and cold-runner valve-gate injection, as well as improved mold-design capabilities are highlighted at Molding 2019 Conference.

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

The most important differences in processing result from differences in temperature control for the two kinds of materials up to curing or vulcanization. When injection molding LSR, a two-component composite is mixed at room temperature in the barrel module. Feeding to the barrel takes place along the shortest possible paths with a small cross-section; distribution is then handled by a valve gate and sub-runner. The LSR vulcanizes in the mold at temperatures of 170 to 190 C (338 to 374 F) to form the elastic part. The mold and its temperature control must therefore be designed for high temperatures. Strict thermal separation between the barrel and mold must also be ensured to prevent the premixed liquid-phase LSR from unintentionally vulcanizing in the barrel.

The Engel e-victory injection machine used here has an electric injection unit in combination with a servohydraulic, tiebarless clamp. Since the tiebarless clamp allows for full utilization of the mold platens right up to the edge, even large, bulky molds with a rotary table will fit on a comparatively small machine.

Engel offers the “smart-shut” sliding-ring nonreturn valve for very low-viscosity melts (or LSR) and short cycle times to provide support for achieving the greatest possible shot-weight consistency (Fig. 4). The non-return valve is particularly useful in applications with a very short injection stroke and very slow injection speeds. The underlying principle is that valve closing is actively initiated by the counter-rotation of the screw; this means that the nonreturn valve is already completely closed when the injection process begins.

SIGMA Engineering and Momentive Performance Materials announced a cooperation to optimize material data for silicone elastomers to make LSR molding simulation more reliable.

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

Sei Woo Hi-Tech Polymer, Austria, a specialist in microtechnology, combines polyamide (nylon) and LSR on one injection molding machine to form a micro-part. The components are part of an air-inlet valve responsible for the massage function in vehicle seats (Fig. 3). For this purpose, the polyamide (PA) housing base bodies are first injection molded in a 16+16 cavity, rotary-plate mold on an Engel e-victory 140 combi injection molding machine. At the second indexing position, the LSR is injected, while 16 more housing base bodies are produced at the same time. Specially formulated PA and LSR form a chemical bond. However, as the contact area is very small, the finished parts are annealed at 200 C (392 F) after molding for safety reasons in order to permanently bond the thermoplastic and silicone. The parts then pass through camera-based 100% quality control.

Having said this, silicone offers benefits in terms of takeoff and part design: The elastic components can be deformed during demolding without impacting quality. This increases design freedom for LSR micro-parts; even small undercuts are possible here. On the other hand, in the case of thermoplastic parts, a strategy for damage-free removal of the rigid, cooled parts must be carefully considered in advance.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

The special features of a tiebarless machine have a positive effect in the injection molding of micro-parts. Due to their design, these machines inherently ensure great platen parallelism and uniform clamp-force distribution. In addition, the tiny parts often need to be produced in a cleanroom. A compact machine design with a large clamping surface reduces the space requirements here; and the clean machine concept without hydraulics, with encapsulated toggle levers and linear guidance, also supports the processor in complying with GMP (FDA’s Good Manufacturing Practice) specifications.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

But before we turn to the differences between LSR and thermoplastic in processing, it's worth taking a comprehensive look at the special challenges of micro-injection molding. These challenges exist independently of the raw material used, because some of the engineering challenges in micro-injection molding arise solely from the part—and part feature—dimensions and extremely low masses processed.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

Hot runner supplier Mastip used K 2022 to introduce the customized and valve-gated Aquilo liquid silicone rubber (LSR) cold deck.

FIG. 4 The “smart-shut” sliding-ring nonreturn valve by Engel for very low-viscosity melts or LSR and short cycle times is used to help achieve the greatest possible shot-weight consistency, which is essential in micro-parts.

Static charge means that the parts stick to smooth surfaces like magnets and can then hardly be gripped even using your fingers. For this reason, micro-injection molded parts are often taken in by vacuum and blown into a small collection container. Once the parts are in the container, things that are otherwise self-evident, such as counting, measuring or weighing a single part, are no longer possible due to the minimal dimensions. Camera inspection for quality assurance therefore takes place on the way from the cavity to the collection container or even directly at the cavity before part removal. To accomplish this, the camera is located on the gripper, which docks onto a specific position on the mold, allowing the camera to assess the quality for multiple cavities. Engel partners with market leaders in automation and quality assurance and offers turnkey production units from a single source.

FIG. 2 The all-electric and tiebarless Engel e-motion TL injection molding machine is tailored for micro-injection molding. It is offered with a special LSR micro-injection unit jointly developed with ACH Solution and a metering pump system from the same partner.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

The requirements placed on the production unit therefore initially appear to be fundamentally different, yet they can be met on a single injection molding machine. This offers the processor more flexibility and the opportunity to better utilize its machines. How does it work?

Even luxury goods such as watches increasingly contain tiny components made of thermoplastic—for example, cog wheels in watch movements or clips—and silicone for tiny seals. It is the latter material, in particular, that is gaining increasing market share because of its special properties. Due to trends toward electromobility and autonomous driving, the automotive industry will also require larger numbers of micro-parts made of liquid silicone rubber (LSR) in the future.

FIG. 1 These LSR micro-parts—connecting elements in instruments for ophthalmic diagnostics—measure 1.7 mm long × 0.9 mm diam. and weigh just 0.0005 g each. They’re molded in 32 cavities.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

Repeatability of the injection movement has an enormous influence on the precision and repeatability of the injection results. But high-quality micro-injection molding is not just a question of the injection unit. Clamp positioning and traverse accuracy also are essential for precise molding of a micro-part. For both LSR and thermoplastics, all-electric, servo-driven machines are therefore a sensible choice in micro-injection molding.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

Ing. Leopold Praher, Sales Manager elast/LIM/thermoset for Engel Austria in Schwertberg, has 35 years’ experience in sales and marketing worldwide in the elastomer industry. He has been with Engel since 1988, starting in spare parts and moving to area sales manager for rubber and silicone machines in 1994. He became worldwide sales director for the Elast Dept. in 2000. Contact: leopold.praher@engel.at; engelglobal.com.

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

The sprue channel alone illustrates how much technical know-how micro-injection molding requires. Its volume must be in a balanced ratio to the volume of the molded part(s). Several boundary conditions have to be weighed against each other and the overall process optimized. Key factors are process management, the waste and energy statistics, the material price and cycle time. All this poses the greatest challenges for the equipment manufacturer and for the manufacturer of the micro-parts.

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

Micro-injection molding means working with part weights of significantly less than one gram. Right now, some manufacturers are already achieving part weights below one milligram—although it makes a big difference here whether the raw material is a thermoplastic with a low specific weight or a liquid silicone with higher density (typically 1.10 to 1.50 g/cm3). Micro-parts made of silicone are generally heavier than thermoplastic micro-parts, but they can be smaller—and more challenging—in terms of dimensions.

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

So you’ve enjoyed the rapid prototyping and low trial costs with 3D Printing and are now ready to go into production with the final design. To help with this process we are going to look at some of the best injection molding companies and compare our experience with them.

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

Given a component 1.7 mm long and 0.9 mm in diam., the part weight made of LSR is 0.0005 g (Fig. 1). If you have 32 cavities, the total shot weight (including sprue) is then 0.125 g. This is the equivalent of about 125 grains of sugar. For comparison's sake, a sugar cube contains about 20,000 to 30,000 grains.

Thermoplastics do not behave any differently than usual during micro-injection molding: The pellets are fed to a screw and heated barrel. The screw and temperature management ensure that the melt forms homogeneously and can be fed to the cavities shot by shot by means of a sub-runner and valve gate.

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

The trend towards miniaturization has gained considerable momentum in recent years. Many products—and with them the parts they are made of—are becoming smaller, more delicately complex and more compact. Micro-injection molding is used to produce many of these complex, delicate parts. In medical technology, examples include the increasing numbers of minimally invasive operations or new methods of analysis. Another target group for micro-molding is consumer electronics with very small electronic and optical precision components for smartphones, among other things.

For example, Engel uses the tiebarless version of the all-electric e-motion TL as the basis for LSR micro-molding. The machine produces tiny silicone components with a new LSR micro-injection unit. However, thanks to a quick coupling system, it can be converted into a thermoplastic injection machine in less than 30 min. And even switching over from micro-injection molding to the production of small components with a size 15 or 18 barrel in the injection unit is possible on the same machine. The material feed required in each case can be smoothly integrated into the machine control system via standardized interfaces (OPC-UA). This turns a standard machine into a highly flexible production unit for small and micro-components made of either LSR or thermoplastic.

Molding delicate LSR parts weighing 0.5 mg in 32 cavities requires high precision and repeatability in molding and careful post-mold handling. Here’s a look at the challenges of micro-molding with LSR and what makes it different from thermoplastic micro-molding.

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In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

For LSR components, the air flow also needs to be changed to reflect the temperatures. Due to the heat generated, the gases mainly escape upward during part removal, which is why the air must be extracted above the mold for LSR injection molding in a cleanroom. By contrast, for thermoplastics, the air extractors are usually located below the mold and the parts in the mold are additionally cooled with fresh air from above in a laminar flow.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Such small quantities as in this example—connecting elements used in instruments for ophthalmic diagnostics—now must be uniformly and repeatably distributed over all the cavities. The micro-injection unit, the sprue channel and thermal management are enormously important here in terms of quality, precision and repeatability.

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

Without us noticing, tiny plastic parts are increasingly making inroads into our lives: in cars, medical technology, mobile phones and wearables. Increasing numbers of these micro-parts are made of silicone. But what challenges does micro-injection molding pose for processors? Is liquid silicone, which is seeing increasingly widespread use, making processes more complex than they already are for thermoplastics? And where will the journey take us—how far can the limits of what is feasible be pushed?