The demand for micro injection molded plastic components varied across industries during the pandemic. While there was increased demand for medical devices and protective equipment, other industries, such as automotive and consumer electronics, experienced reduced demand. Many manufacturers of micro injection molded plastic components had to reduce or halt production temporarily due to health and safety concerns for their workers. This led to a decrease in the supply of micro-molded products.

Micro Injection Molded Plastic Market was valued at USD 1.2 billion in 2023 and is anticipated to register a CAGR of over 11% between 2024 and 2032. As electronic devices become smaller and more compact, there is a growing need for micro-molded plastic components to fit within tight spaces. This includes components for smartphones, wearable devices, medical devices, and more.

Blow molding is energy intensive and regularly produces electrical peaks at the facility. To better handle the costs associated with these peaks, AIPC installed a unique solar and energy storage system in 2019.

The medical and healthcare sector is a significant driver of the micro injection molded plastic industry. The demand for micro-molded components for medical devices, diagnostics, and drug delivery systems is rising due to advancements in healthcare technology and an aging population. Advancements in polymer technology have led to the development of high-performance materials suitable for micro injection molding. These materials offer enhanced mechanical properties, biocompatibility, and resistance to extreme conditions, expanding the range of applications.

“I consider it a strategic investment for our future,” explains Schaefer-Weaton. “We are in it for the long haul—for our customers, our employees and the community of Fairfield.”

A good example is Fairfield, IA-based Agri-Industrial Plastics Co. (AIPC), which specializes in the blow molding of large-scale industrial parts. These include fuel tanks for the turf equipment, power sports, agricultural and marine industries.

The medical and healthcare industry relies on micro-injection molding for the production of precise and sterile components such as syringe barrels, catheters, and other medical devices. The demand for such products continues to rise with the aging global population and advancements in medical technology. The automotive industry uses micro-injection molding for producing small and intricate parts, including connectors, sensors, and interior components. As vehicles become more sophisticated with advanced electronics and sensors, the demand for micro-molded plastic parts increases.

Setting up the tooling and molds for micro-injection molding can be expensive, especially for small production runs. This initial cost can be a barrier for small and medium-sized enterprises (SMEs) and startups. The choice of the right material is crucial for micro-injection molding. Finding materials that meet the stringent requirements for micro-sized components can be challenging.

North America dominated the global micro injection molded plastic market in 2022. Within North America, the U.S. generated a revenue of over USD 0.2 billion in 2022 The aging population in North America drives the demand for medical devices, diagnostics, and drug delivery systems, which often rely on micro injection molded components. North America is a major center for technology and electronics innovation, leading to increased demand for micro injection molded plastic components in applications like smartphones, wearable technology, and other electronic devices.

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The primary purpose of the Powerpacks is to help AIPC achieve peak shaving with greater efficiency and reliability. AI-based controls ensure this by automatically charging the Powerpack’s 16 lithium-ion battery pods when electricity rates are at their lowest and discharging energy at times of high usage (or peak demand) to avoid or reduce costly demand charges.

Schaefer-Weaton says that AIPC’s energy load is fairly consistent over the course of the year, with peak loads in the 2,500 to 3,000 kilowatt range. Weekend loads can drop to as low as 100 kilowatts, though they are higher when the company runs weekend shifts during busy times.

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The trend of miniaturization in various industries, including electronics, medical devices, and automotive, is driving the demand for micro injection molded plastic components. As products become smaller and more complex, the need for precise, small plastic parts continues to grow.

Founded in 1978, the company operates a 340,000-square-foot advanced manufacturing facility. The plant is equipped with 20 monolayer accumulator-head blow molding machines and seven multilayer continuous extrusion machines. Robotic automation is also present, to complement a clean and modern work environment.

Jim was a senior editor of ASSEMBLY and has more than 30 years of editorial experience. Before joining ASSEMBLY, Camillo was the editor of PM Engineer, Association for Facilities Engineering Journal and Milling Journal. Jim has an English degree from DePaul University.

It is safe to say that the debate about the environmental impact of plastic will continue. But, it is also a fact that many manufacturers of plastic products are quietly becoming greener.

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A white paper from developer Ideal Energy estimates that the project will save AIPC an average of $55,000 per year for the foreseeable future. Equally important, it will prevent 9,377 tons of CO2 from entering the atmosphere over the next 25 years. The CO2 number is equivalent to that produced by burning more than 10 million pounds of coal.

Each Powerpack is modular, scalable and durable enough for outdoor use. It is also AC-coupled, rather than DC-coupled, meaning it operates completely independent of the solar array. This ensures that if the array or energy storage system goes down (for whatever reason), the other part of the installation will continue to operate.

Based on material type, the market is divided into Liquid-crystal polymer (LCP), Polyether ether ketone (PEEK), Polycarbonate (PC), Polyethylene (PE), Polyoxymethylene (POM), Others. Polycarbonate held the dominant market share of USD 0.3 billion in 2022. Polycarbonate is known for its optical clarity and high light transmission properties, making it ideal for applications where transparency is essential, such as optical components, lenses, and displays. The exceptional impact resistance of polycarbonate is a significant driver for its use in industries such as consumer electronics, automotive, and medical devices, where durable and shatter-resistant components are needed.

As for the hoped-for benefit of attracting forward-thinking employees, Schaefer-Weaton is confident it will come to fruition in the long run. She believes the project shows all of its customers, many of which have green initiatives of their own, that AIPC is planning to be around for many years.

The AIPC plant features a 517-kilowatt, roof-mounted solar array that works in tandem with a 430-kilowatt-hour energy storage system composed of two battery-powered Tesla Powerpacks. During the day, the solar panels generate energy, which charges the Powerpacks and powers all manufacturing operations.

BASF SE and Isometric Micro Molding, Inc.are dominant players in the micro injection molded plastic business due to their vast product portfolio. BASFs ecosystem integration, along with consistent innovation, have attracted millions of customers. Their brand recognition and exclusive content deals solidify their leadership in the highly competitive market.

Based on application, the market is categorized into medical and healthcare, automotive, electronics, telecommunications, aerospace and defense, others. Medical and healthcare accounted for over 45% market share in 2022 and is projected to grow through 2032. The trend towards smaller, minimally invasive medical devices and drug delivery systems creates a strong demand for micro injection molded components. The medical sector demands materials that are biocompatible and safe for use in implantable devices and diagnostic equipment.

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“We run 27 [production] lines 24 hours a day [on weekdays],” says Lori Schaefer-Weaton, president of AIPC. “This [creates] huge utility bills. Some of the [system] payback will be strategic, longer term, by building excitement around working [here] and being part of something bigger.”

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