Special injection molding processes

Innovative prototype and small series production

Efficient production of prototypes and small series using modern injection molding technologies. Fast time to market, maximum precision, and cost efficiency – perfectly tailored to your requirements.
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Prototypes and small series with modern injection molding technologies

Whether you're interested in prototype injection molding or a small series, our special injection molding processes can be easily applied to both. Our special processes offer a wide range of options for designing your components even more efficiently. For example, by combining multiple materials or overmolding metal inserts, several tasks can be combined in a single component. This saves time and money when reusing the components. The following special processes are among our strengths.

Your solution for precise prototypes and small series

Injection molding special processes

Two- and multi-component injection molding
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Multi-component injection molding produces components made of different materials, such as hard components with a sealed geometry. A separate mold is manufactured for each component. After the first component is molded, it is inserted into additional molds and overmolded.
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Insert technology
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With insert technology, inserts are placed into the injection mold and overmolded with plastic. These inserts are typically threaded bushings, contacts, sheets, or coils. Overmolded parts such as magnets or circuit boards are also possible.
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Outsert technique
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In the outsert technique, plastic elements are sprayed onto a metal carrier and anchored via undercuts or openings.
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Micro injection molding
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Micro injection molding refers to the production of injection-molded components with a shot weight of less than one gram.
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In-mold process
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In the in-mold process, also known as in-mold labeling, foils, fabrics, or paper are inserted into the mold and back-injected with plastic. This creates sophisticated surfaces in a single step.
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Gears
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The production of gears places special demands on plastic injection molding. Due to the concentricity tolerances typical of gears, the injection molding concept must be designed to accommodate these specific requirements. The production of precision gears is one of our specialties.
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Cable/hose overmolding
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When overmolding cables or hoses, sealing the cable/hose presents a challenge. These are usually subject to strong tolerance fluctuations, so a special sealing concept is used here.
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TSG procedure
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By adding blowing agents, a foam structure is created in the component core. This process is typically used for wall thicknesses between 4 and 20 mm. The process is used to provide thick-walled components with a foam core, thus preventing sink marks caused by material accumulation.
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Melt core injection molding
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In the melt core process, a core made of a low-melting metal is inserted into the mold and overmolded. The metal core is then melted in a heating bath. This process is used to create undercuts or cavities that cannot be created with demoldable cores.
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It works that simply
Get your prototype in 4 steps!
1.
Initial contact and advice
Contact us – by phone, email, or using our contact form. In an initial consultation, we'll discuss your idea, clarify your requirements and goals, and find the optimal solution for your project.
2.
Project planning and offer
Based on your requirements, we will prepare a detailed project plan and a non-binding quote. We will advise you on material selection, suitable processes, and clarify all technical details.
3.
Implementation
Once you've approved it, we'll implement your project using our modern rapid tooling processes. Whether it's prototypes or small series, we work precisely and efficiently so you can get the results quickly.
4.
Feedback and optimization
You will receive the finished parts for inspection and testing. If necessary, we will make adjustments to achieve the perfect final result. We will support you until your project is successfully implemented.
Frequently asked questions
Everything you want to know
What special injection molding processes does memoplast offer?
Memoplast offers a variety of special injection molding processes, including multi-component injection molding, insert molding, and the TSG process. Our processes are specifically designed to meet the needs of prototype and small-batch production.
How quickly can prototypes and small series be produced using injection molding?
Thanks to our rapid tooling process and state-of-the-art technology, we can typically deliver prototypes and small series within 3 to 4 weeks, depending on the order situation and the complexity of the project.
Which materials can be used in injection molding for prototypes?
We work with a wide variety of plastics, including ABS, POM, PC, and many more. Our team will be happy to advise you on selecting the optimal material for your prototype or low-volume project.
Why should I choose memoplast for my injection molding prototypes?
Memoplast offers customized injection molding solutions, from rapid prototyping to small-batch production. Our experience, flexibility, and state-of-the-art technologies guarantee the precise implementation of your projects.
What tolerances can be maintained with special injection molding processes?
We manufacture according to the DIN 20457-TG6 standard and can also accommodate finer tolerances upon request. Simply contact us to discuss your specific requirements.
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