Micro Injection Molding Services

Frigate delivers micro injection molding with precision tolerances down to ±5 microns. Our expertise ensures ultra-fine detail and accuracy in complex miniature components.

Our Clients

Advantages of Micro Injection Molding Services

Exceptional Surface Finish

Micro injection molding provides smooth surface finishes and high detail resolution, which are critical for optical and medical applications where clarity and accuracy are essential.

Thermal Stability in Processing

Micro injection molding can maintain thermal consistency, preventing warping or distortion, which is crucial for tiny parts with tight dimensional requirements.

Capability for Multi-Material Molding

It allows for integrating multiple materials in a single part, facilitating complex designs with different material properties for specific functional needs.

High-Strength Micro Parts

The process produces durable micro-components with consistent mechanical properties, supporting applications where small parts must withstand rigorous operational stresses.

Precision-Driven Custom Micro Injection Molding

Ultra-precise miniature components often suffer from inconsistent tolerances, poor material efficiency, and compromised performance. Custom micro injection molding addresses these issues by providing exact control over complex geometries, with tolerances as fine as ±5 microns. This advanced process reduces waste, ensures outstanding surface finishes, and maintains thermal stability, even in intricate designs with multiple materials. Custom micro injection molding ensures high-volume, repeatable production with precise specifications for medical, aerospace, and electronics applications.

Get Your Quote Now

Our Micro Injection Molding Process

Material Preparation

Specialized micro-sized materials are selected and precisely preheated to the required viscosity for efficient flow during injection.

Mold Design and Setup

To shape the micro components, a highly detailed mold with fine tolerances is created. The mold is carefully set up for optimal precision.

Injection Phase

The molten material is injected into the mold under high pressure through small nozzles, filling the tiny cavities accurately.

Cooling and Solidification

The injected material cools rapidly within the mold, solidifying it into the desired shape while maintaining fine details and dimensional accuracy.

Ejection of Part

Once cooled, the micro-component is ejected from the mold and ready for inspection and further processing.

Post-Processing

Final steps such as trimming, surface finishing, or additional assembly are carried out to ensure the part meets strict technical specifications.

Micro Injection Molding Materials

Micro injection molding demands precision and reliability for producing miniature components. Choosing the right materials ensures optimal performance and durability in complex applications.

Glass-Filled Polymers

Glass-filled nylon (PA) and PEEK offer increased rigidity and dimensional stability, ideal for high-stress, high-temperature aerospace, automotive, and electronics applications.

High-Temperature Thermoplastics

Polyphenylene sulfide (PPS) and polyetherimide (PEI) maintain strength and dimensional stability at elevated temperatures and are suitable for industrial, aerospace, and electronics components.

Fluoropolymers (PTFE, PFA, FEP)

Fluoropolymers provide excellent chemical resistance, low friction, and high thermal stability, which makes them ideal for medical, chemical processing, and food-grade applications.

Carbon-Filled Composites

Carbon-filled PEEK and polypropylene offer enhanced electrical conductivity, stiffness, and wear resistance, making them ideal for high-performance parts in aerospace, defense, and electronics.

Biocompatible Polymers

Medical-grade polyethylene, polyurethane, and bio-based resins are used in medical devices and healthcare applications, meeting safety and non-toxicity standards for critical components.

Thermoplastic Elastomers (TPEs)

TPEs combine flexibility with processability, offering abrasion resistance and long-term performance in automotive, medical, and consumer electronics applications.

Metal-Plastic Composites

Metal-filled thermoplastics, such as stainless steel or aluminum, combine strength and lightweight properties, which are ideal for sensors, connectors, and medical instruments requiring high performance.

Precision in Tight Tolerances for Complex Micro Parts

Micro injection molding requires precise control to meet tight tolerances down to the micron level. Frigate utilizes advanced injection molding systems and high-precision tooling to ensure dimensional accuracy. Optimized mold cavity design and high-quality materials minimize deviations from wear. Temperature, pressure, and velocity are tightly regulated to maintain consistency and avoid defects. These measures guarantee that each part meets the exact specifications of the aerospace, medical, and electronics industries.

Compliance for Micro Injection Molding Services

Micro Injection Molding demands precise control over material flow, pressure, and temperature to create high-precision components. Frigate maintains strict compliance with global standards to guarantee dimensional accuracy and reliability. Using advanced equipment and techniques, Frigate ensures consistent results, meeting the tight tolerances required in the medical, electronics, and automotive industries. These certifications ensure that the manufacturing process adheres to best practices in safety, quality, and environmental responsibility.

ISO 13485:2016

ISO 13485:2016 focuses on managing medical device quality, ensuring traceability, risk management, and compliance with stringent product specifications.

UL 94 V-0

Verifies the flame-retardant properties of materials, ensuring they do not sustain combustion under specified testing conditions critical for electronic components.

RoHS 2011/65/EU

Regulates using hazardous materials in components, limiting lead, mercury, and other harmful substances in products.

FDA 21 CFR Part 820

Defines the quality system regulation (QSR) for manufacturing medical devices, covering design, production, and post-market requirements.

ISO 9001:2015

Establishes criteria for quality management systems, emphasizing process control, corrective actions, and customer satisfaction metrics.

REACH Regulation (EC) No 1907/2006

Requires manufacturers to register chemicals used in production, ensuring their safe use and reducing environmental impact.

Tolerance for Micro Injection Molding Services

Injection Pressure

30 to 200 MPa

Controls the pressure applied during the injection process to ensure material flow and mold filling.

Injection Speed

10 to 50 mm/s

Ensures consistent speed during injection, which affects the quality and uniformity of molded parts.

Cycle Time

5 to 20 seconds

The total time taken for one cycle of injection, cooling, and ejection, critical for high-speed production.

Mold Temperature

120 to 180°C

Optimizes the temperature for both the mold and injected material to ensure uniform cooling and shrinkage.

Material Shrinkage

0.3% to 1.5%

Accounts for material contraction during cooling, which is important for achieving precise final dimensions.

Plastic Flow Length

2 to 10 times the diameter

Ensures proper flow and filling of the mold cavity for complex, fine features in micro-sized components.

Ejector Force

50 to 500 N

Ensures sufficient force to eject molded parts from the cavity without damage to delicate micro components.

Gate Size and Type

0.1 to 0.5 mm

Determines the size and type of gate for optimal flow and minimal part defects during injection molding.

Vent Depth

0.01 to 0.1 mm

Ensures proper venting of trapped air in the mold, critical for avoiding defects like short shots.

Clamping Force

1 to 50 kN

The force needed to keep the mold halves together during injection, crucial for preventing flash or defects.

Mold Deflection

±0.01 to ±0.05 mm

Ensures minimal deformation of the mold under clamping pressure, important for maintaining tight tolerances.

Cooling Rate

1 to 3°C per second

The rate at which the molded material cools, affecting cycle time, part strength, and final part quality.

Warping Tolerance

±0.05 mm

Controls deformation of parts after cooling, important for maintaining dimensional accuracy in micro parts.

Flash Thickness

0.01 to 0.1 mm

Controls the thickness of the unwanted material at the parting line, ensuring minimal flash in high-precision molding.

Material Flow Length-to-Width Ratio

300:1 to 500:1

Ensures that very long, thin sections of the mold fill consistently, without voids or defects in micro-scale components.

Surface Roughness (Ra)

Ra 0.1 to Ra 0.8 µm

Achieves ultra-fine surface finish, necessary for micro components, particularly in the medical or electronic industries.

Quality Testing Standards for Micro Injection Molding Services

Mold Fill Time

Pressure Decay or Flow Analysis

Measures the time it takes for the mold cavity to fill, critical for optimizing cycle time and precision.

Viscosity Profile

Capillary Rheometer or Rotational Rheometer

Evaluates the flow behavior of the material under varying shear rates, ensuring consistent material flow.

Critical Dimension Tolerance

High Precision Optical CMM or Laser Scanning

Assesses the tolerance of key features critical to the function of micro components.

Cavity Pressure Distribution

Pressure Transducer or MoldFlow Simulation

Analyzes the uniformity of pressure applied across the mold cavity, ensuring consistent part quality.

Melt Temperature Control

Thermocouples or Infrared Thermography

Monitors and controls the temperature of the molten material to ensure optimal molding conditions.

Residual Stress

X-Ray Diffraction (XRD) or Polarized Light

Detects internal stress in molded parts, which can impact their strength and dimensional stability.

Compression Set

Compression Testing (ASTM D395)

Measures the permanent deformation of materials after compression, assessing elasticity and recovery.

Cycle Time Consistency

Automated Cycle Time Monitoring

Monitors and compares cycle times to ensure repeatability and consistency across multiple production runs.

Moisture Content

Karl Fischer Titration or Infrared Drying Method

Measures the moisture content in the polymer, critical for preventing defects during molding.

Mold Wear and Erosion

Scanning Electron Microscopy (SEM) or Surface Profiling

Analyzes mold surfaces for wear, erosion, or corrosion, ensuring long-term accuracy in mold performance.

Heat Transfer Efficiency

Thermal Conductivity Testing or Thermocouples

Measures the ability of the mold and material to transfer heat, ensuring efficient cooling and quality.

Polymer Chain Integrity

Gel Permeation Chromatography (GPC)

Analyzes the molecular weight distribution and chain integrity of the polymer, impacting part strength.

Surface Adhesion

Contact Angle Measurement or Peel Test

Tests the ability of coatings, inks, or adhesives to bond to the part surface, ensuring adhesion quality.

Micro Defects Detection

Acoustic Emission or Ultrasonic Testing

Detects internal micro-defects such as voids, cracks, or inclusions that can affect component strength.

Thermal Expansion

Dilatometry or Thermomechanical Analysis (TMA)

Measures the material’s thermal expansion behavior, crucial for dimensional stability under temperature variations.

Parting Line Defects

Optical Microscopy or 3D Scanning

Detects defects along the parting line, critical for preventing parting flash or misalignment issues.

Maximizing Quality and Efficiency in Medical Component Fabrication

Manufacturing medical components require precision, consistency, and strict regulatory compliance. Micro injection molding meets these needs by producing intricate, small-scale parts with tight tolerances. It is vital for creating components like implants, surgical tools, and diagnostic devices, where accuracy and reliability are critical. Biocompatible materials are used, and material waste is minimized. This enhances production efficiency while maintaining high-quality standards. The process ensures each part meets the required specifications for safety and performance in medical applications.

Industries We Serve

What You Get

Reducing Material Waste for Efficient and Cost-Effective Production

Due to small part sizes, minimizing material waste is critical in micro injection molding. Frigate optimizes shot size to reduce excess material and employs cold-runner systems to direct material efficiently. Injection speed, holding pressure, and cooling rates are fine-tuned to minimize scrap. These practices ensure that material use is efficient, reducing costs while maintaining high-quality production.

Check Out Our Blogs

Exploring the Advantages of Forging Over Machining

Forging over machining, when it comes to manufacturing, choosing the right process is crucial for achieving...

Cloud Manufacturing Services for Real-Time Procurement Management

Have you ever faced delays in getting the right products at the right time? Or have you struggled to...

Top Metal Stamping Components Available in Michigan

Are you facing challenges in sourcing metal stamping components that meet exact specifications while...

Mastering the Art of Using a Sheet Metal Bender

Are you struggling to get accurate bends in your sheet metal projects? Does your metal often crack or...

Forging vs Casting- A Comprehensive Guide to Metal Shaping Techniques

The world of metalworking is full of fascinating techniques for shaping raw materials into useful components....

Exploring the Role of Die Casting in the Automotive Industry

The automotive sector is very competitive, focusing on improving fuel efficiency and cutting emissions....

Streamlining Your Supply Chain with Forged Components

Is your supply chain struggling with delays, rising costs, or inconsistent quality? These challenges...

How Welding Cables Ensure Power and Safety in High-Temperature Operations

High-temperature environments in aerospace, automotive, and heavy manufacturing introduce complex challenges....

Understanding the HDPC Casting Process for Precision Parts

Are you facing challenges in meeting the high-precision demands of your industry? Do production inefficiencies...

Diverse Applications of Injection Molding in Modern Industries

Shaping Industries Across the Globe Injection molding is a versatile and widely used manufacturing...

What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does micro injection molding handle intricate geometries with tight tolerances?

Micro injection molding uses specialized molds and precise injection techniques to achieve tolerances as small as ±5 microns. This ensures the production of complex, high-precision parts without compromising detail or structural integrity.

What solutions does micro injection molding offer to reduce material waste in small production of small parts?

The process is highly efficient. By injecting precise amounts of material into the mold cavity, it optimizes material flow and minimizes waste. This ensures material conservation while maintaining the integrity and functionality of micro components.

How does micro injection molding ensure the performance of parts in extreme temperatures?

Micro-injection molding can produce parts with excellent heat resistance and thermal stability by selecting high-performance thermoplastics and additives. This is crucial for aerospace, electronics, and medical applications where parts must function in harsh conditions.

Can micro injection molding accommodate multi-material components in a single part?

Yes, multi-material molding enables the integration of different materials within a single component, enhancing functionality, flexibility, and performance. This is especially useful for micro parts requiring different material properties, such as electrical conductivity or flexibility.

How does micro injection molding address the challenge of producing small batches with consistent quality?

Micro injection molding ensures high repeatability through precise control over the injection process, mold design, and material handling. This allows for consistent production of small batches and meets stringent quality requirements across every part.

We'd love to Manufacture for you!

Submit the form below and our representative will be in touch shortly.

LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ