Precision Injection Molding of Plastic Parts

The basis for precision injection molding is the ideal design of the injection molding machine. To ensure the reproducibility of shot weights, precise plasticizing 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 reproducibility and process control in the production of precision parts.

At ENGEL, precision in injection molding includes optimized plasticizing processes to reduce or completely eliminate internal part defects. The optimelt sequence program enables significant improvements in this area. The software-supported solution provides the user with a flexible modular system for the plasticizing sequence. It allows, for example, additional melt compression steps, therefore improving the plasticizing process.

The digital solution iQ weight control optimizes the injection volume during the injection molding process. This compensates for fluctuations in melt viscosity. iQ weight control reacts to external influences. The software ensures that the accuracy of the injection molding process is increased, and the part weight remains constant despite viscosity fluctuations. For molds with multiple cavities, iQ weight control is the right choice. It minimizes scrap due to overfilled or incompletely filled mold cavities.

With multi-layer technology, you can achieve an exact reproduction of the mold surface of your precision injection molded parts. It is mainly used to produce thick-walled lenses. The substrate is molded on the first machine, which is then overmolded on a second machine. The high precision of the finished part is defined during overmolding. Surface quality is guaranteed regardless of shrinkage. You achieve higher dimensional accuracy and beneficial optical properties.

The most striking example of precision requirements is micro injection molding. Part weights of a few thousandths of a gram and fine structures can only be achieved by high-precision machine movements. Our injection unit fills the gap for micro components and enables shot weights in the 0.3 gram range. Thanks to its precise design, the smallest microstructures for your parts can be produced without defects.

Variotherm processes are well suited to avoiding larger or smaller weld lines. They are used for high-gloss effects on surfaces and ensure complete filling of mold cavities. The processes are based on pressurized water or heat transfer oils and allow hot-cold switching of mold areas. They improve the detail accuracy of parts in precision injection molding. Other variotherm processes are based on inductive heating solutions or the partial use of heating elements.