MTD Micro Injection Molding Process

Design

The journey begins with this critical step. Our highly experienced engineers utilize PFMEA to recognize and assess any possible production problems and their effects, and then establish solutions to reduce or eliminate these situations. Issues such as the fill, ejection, handling, inspection, and packaging are reviewed. We use MoldFlow analysis, along with a combination of runner optimization, micro spiral flow, and variable test plaque molds to predict how a product will fill.

Mold Manufacturing

After we've completed the initial step, we design the mold for maximum manufacturability, and perform an array of measures, such as:

• Establish insert areas, vent locations, and cooling requirements
• Address issues that were identified relating to the fill, warp, and venting
• Determine the manufacturing methods for the various components
• Identify which components need to made in multiples because of a high risk of loss due to their manufacturing tolerances

Process Development

In this phase, we conduct a rigorous set of preliminary process development exercises, and apply scientific molding techniques to develop a baseline process.

Validation

Before arriving at the production phase, we perform a design of experiment procedure to determine critical variables and establish a process window. Additionally, we determine the operational qualification by challenging the extreme process settings. Then, we conduct the performance qualification by verifying multiple process runs at nominal settings.

Production

Once we've validated the micro plastic injection molding process, the actual production work begins, which features:

• Integrated vision capabilities
• Automated inspection and part removal
• ETDL-process condition monitoring software
• SPC-process control software
• RJG-EDART
• Instrumental cavities and cavity separation
• Part and runner verification

As part of our production process, we often provide valuable extras, such as custom packaging, degating operations, and a complete in-line critical dimension inspection using cameras.