Micro Injection Molding Service
Micro injection molding, also known as micro molding, is a highly specialized evolution of traditional injection molding, developed to produce ultra-small, highly precise plastic components. It allows parts with complex geometries and extremely tight tolerances—often between 10 µm and 100 µm—making it indispensable to medical devices, automotive systems, aerospace and consumer electronics. The process demands purpose-built equipment featuring small-diameter screws or plungers and dedicated plasticizing stages to control ultra-low shot volumes. High-performance polymers such as POM, PEEK and LCP provide superior flow and mechanical integrity to meet these stringent specifications.
How Does Micro Injection Differ from Traditional Injection Molding?
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- Scale : Produces components under 1 g with micrometer-scale features.
- Precision : Delivers tighter tolerances than standard injection molding.
- Equipment : Utilizes machines specifically designed for micro-scale molding with enhanced temperature and pressure control.
- Materials : Employs advanced polymers engineered for flowability and dimensional stability in miniature components.
The Process of Micro Injection Molding
- Design and Tooling : Projects start with part design and mold development in hardened steel or aluminum, compensating for shrinkage, thermal expansion and fine geometry. Micron-level accuracy is achieved via CAD/CAM and micro-machining (e.g. EDM).
- Material Selection : Materials must offer excellent flow, thermal stability and deformation resistance—typical choices include PE, PP, Nylon, PC, POM, PSU, PEEK, PEI and LCP.
- Injection : Specialized micro screws or plungers deliver milligram-level shot sizes while maintaining melt uniformity.
- Cooling and Solidification : Ultra-small volumes cool rapidly; controlled cooling ensures dimensional stability and prevents warpage.
- Ejection and Quality Control : Parts are delicately ejected; microscopes or automated vision systems verify compliance with tight tolerances.
The Applications of Micro Injection Molding
Medical Devices
- Microfluidic devices (lab-on-chip systems)
- High-precision surgical tools
- Drug-delivery systems
- Biocompatible PEEK implants & single-use parts
Electronics
- Connectors & chip housings
- Sensors for wearables & IoT
- Micro lenses for compact cameras
- Miniature switches & precision parts
Automotive
- Micro gears & actuator components
- Miniature valves for fluid control
- Sensors for ADAS
Aerospace & Consumer Products
- Micro-fasteners & precision fittings
- Fluid-management components for satellites
- Insulation parts for avionics
- Components in wearables, watches, toys & household gadgets
Commonly Materials In Micro Injection Molding
| Type | Material | Key Properties | Applications |
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| Thermoplastic | Polyethylene (PE) | Chemical resistance, flexibility | Micro actuators, select medical parts |
| Polypropylene (PP) | Flexibility, high melting point, chemical resistance | Syringes, connectors, consumer goods | |
| Nylon (Polyamide) | High strength, heat & wear resistance | Micro gears, connectors, automotive sensors | |
| Polycarbonate (PC) | Optical clarity, impact resistance | Lenses, housings, electronic enclosures | |
| Delrin (POM) | Dimensional stability, low friction | Filters, gears, mechanical micro parts | |
| Polysulfone (PSU) | Heat resistance, transparency | Microfluidic devices, housings | |
| Polyetheretherketone (PEEK) | Biocompatibility, chemical & thermal resistance | Implants, aerospace, automotive components | |
| PEI (Ultem) | Flame retardancy, dimensional stability | Surgical tools, micro-optics | |
| Liquid Crystal Polymer (LCP) | Low warpage, high flow, mechanical strength | RF connectors, precision electronics | |
| PMMA (Acrylic) | Optical clarity, rigidity | Light guides, fiber-optic connectors | |
| Thermoset / Elastomer |
Silicone Rubber (LSR) | Elasticity, biocompatibility, heat resistance | Gaskets, valves, wearable seals |
| Polyurethane | Abrasion resistance, flexible hardness | Protective & defense components | |
| Thermoset | Epoxy | Electrical insulation, thermal stability | Encapsulation, molded-in tools |
| Phenolic | Chemical & heat resistance, dielectric strength | Insulators, component grips | |
| Elastomer | TPEs | Flexibility, easy processing | Personal care products, consumer electronics |
Layana’s Micro Injection Capabilities
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| Item/Type | Vertical Injection Machinery | Horizontal Injection Machinery |
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| Tonnage Range | From 35T to 250T | From 60T to 200T |
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Maximum Product Size |
INCH: 8.5 x 11 x 6 MILLMETER: 216 x 279 x 150 |
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Maximum Product Weight |
0.1g~500g | |
| Preciseness |
Mold: ± 0.005mm Product: ± 0.03~0.05mm |
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Advanced Integrated Manufacturing : LAYANA integrates plastic injection molding with metal stamping,delivering industry-leading overmolding and insert molding processes and enabling the production of even the smallest and most intricate components as unified, robust units.
Proven Expertise & Uncompromising Quality : As an IATF 16949-certified manufacturer with extensive experience across diverse sectors including automotive, electronics, medical, aerospace, cycling, and consumer goods, LAYANA consistently delivers outstanding quality and reliability. Our comprehensive quality management systems, complemented by robust environmental and sustainability practices, ensure that every micro injection molded component meets or exceeds the most stringent industry standards.
In-House Tooling & Automation Excellence :LAYANA’s in-house dedicated engineering and automation teams continuously refine manufacturing processes to enhance precision and efficiency. Our state-of-the-art tooling, sophisticated machinery, and significant R&D investments guarantee that micro injection molding manufacturing remains highly efficient, repeatable, and scalable, facilitating high-volume production without compromising on quality.
Efficient Supply Chain & Cost Reduction : LAYANA provides an end-to-end solution, from initial design for manufacturability (DFM) to mass production, streamlining the supply chain and minimizing dependence on multiple suppliers.
Partnering with LAYANA means choosing a trusted leader capable of delivering ultra-precise molding along with comprehensive engineering support and production expertise. We ensure your high-quality, durable, and efficient components meet the rigorous demands of industries ranging from automotive to electronics.