Mikrospritzgießen

Mikrospritzgießen is a manufacturing process used to produce extremely small plastic parts. It is an advanced form of injection molding that employs specialized machinery and techniques to handle the unique challenges associated with micro-scale production. The process involves injecting molten plastic into a micro-cavity mold under precise control of temperature, pressure, and speed. The extremely small dimensions of the parts require high accuracy in mold design, manufacturing, and process execution.

Key aspects of mikrospritzgießen include the use of high-precision molds, often made from hardened steel or specialized alloys, with tolerances in the micrometer range. The injection units are designed for very small shot volumes and rapid injection speeds to ensure efficient filling of the micro-cavities before the plastic cools. Material selection is also critical, with a focus on thermoplastics that exhibit good flow properties at micro-scales and can withstand the high shear rates involved. Common materials include high-performance polymers like PEEK, liquid crystal polymers (LCPs), and certain grades of polycarbonate or POM.

Applications for mikrospritzgießen are found in industries requiring miniaturized components, such as medical devices (e.g., surgical instruments, microfluidic chips), electronics (e.g., connectors, sensor housings), and optics (e.g., lenses, diffractive optical elements). The process allows for the mass production of intricate, high-precision micro-parts that would be difficult or impossible to achieve with traditional manufacturing methods. Challenges include ensuring uniform part quality, managing shrinkage and warpage at the micro-level, and preventing contamination.