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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.

Advantages of Our Precision Injection Moulding Processes
Reproducible components thanks to optimum machine design
Picture shows ENGEL smart-shut non-return valve

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.

High melt quality as a prerequisite for precision injection moulding
Picture shows plasticising screw from ENGEL

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.

Constant component weight with digital assistance software
Picture shows application of the iQ weight control software from ENGEL

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.

High-quality surfaces thanks to multi-layer injection moulding
High-quality surfaces thanks to multi-layer injection moulding

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.

Flawless microstructure thanks to system for smallest shot weights
Picture shows an application for precision injection moulding from ENGEL

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.

Surface details thanks to heating and cooling in each cycle
Picture shows surface of a plastic component from ENGEL

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.

Do You Need High Precision Injection Moulding for the Production of Your Plastic Products?

We support you with solutions for a constant part weight and fully formed surfaces. Even for the smallest components.

Suitable Processes for Precision Injection Moulding - An Overview

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

Our Variety of Processes in Precision Injection Moulding
Picture shows optical plastic component
New Software Reduces Micro-Defects in the Field of Precision Injection Moulding

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.

Image shows Liquid Injection Moulding for micro injection moulding
Liquid Injection Moulding für Mikrospritzguss
LIM

Präzisionsspritzguss für die kleinsten Bauteile. Flüssig-Silikon flexibel und präzise verarbeiten, selbst bei Mehrkomponenten-Anwendungen. Vollautomatisch in einem Arbeitsschritt nacharbeits- und abfallfrei.

Advantages of the LIM Procedure
Can be Realised with Existing Standard Machines

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.

Precision Through Servo-Controlled Injection Unit

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.

Integration Into the Machine Control System

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.

Result:

  • Precision and ergonomics

  • Low-flash, rework- and waste-free products

Examples of Precision Injection Moulding with LIM
  • Production of Pipette Tips

    Sophisticated mould and material, precise injection moulding machine and intelligent software solutions. For a smooth production process.

  • LSR Micro Injection Moulding for Almost Weightless Parts

    Part weight is only 0.0005 g. With our turnkey LSR micro injection moulding production cell including tie-bar-less, fully electric e-motion 30 TL LIM.

  • Precision Injection Moulding for the Production of FFP2 Masks with Replaceable Filter

    The FFP2 masks are produced on two tie-bar-less e-victory hybrid machines. With replaceable filter and soft silicone lip. For more comfort and environmental friendliness.

Picture shows optical application
Process for Transparent Precision Parts
optimelt

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.

Advantages of the optimelt Process
Versatile

Suitable for a variety of demanding applications in the field of camera and lighting optics.

Low Stress Moulded Parts

Precise injection-compression moulding of lenses and optical components.

Complete Mould Filling

Variotherm mould temperature control for finest structures and increased accuracy.Variotherme Werkzeugtemperierung für feinste Strukturen und erhöhte Genauigkeit.

Efficient Production Thanks to Multi-Layer Technology

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.

Result:

  • 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.

Video shows process for thick-walled precision injection moulded parts
Picture shows Vice President Global Application Technology at ENGEL Austria

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.

Norbert Müller, Vice President Global Application Technology at ENGEL Austria

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.

Discover More Injection Moulding Processes for Your Plastics Production

Over 20 proven injection moulding processes for more economic efficiency and different areas of application

Picture shows surface finishing of a plastic component from ENGEL

Surface Finishing and Functionalisation

Injection moulding process for sophisticated component designs with additional functional integration

Picture shows transparent component from ENGEL

Optical and Transparent Components

Injection-moulded components made of transparent plastics for perfect visibility

Picture shows lightweight plastic component from ENGEL

Weight and Warpage Reduction

Injection moulding process for lightweight plastic components to reduce weight and warpage of your plastic parts

Picture shows plastic component made of special material

Elastomers and Thermosets

A wide range of non-thermoplastics such as silicone, rubber, BMC or HTV can be processed in injection moulding

Christopher Stafford

Sales Operations Manager

Write to us

The ENGEL team will be happy to assist you with comprehensive know-how on the subject of injection moulding.