Silicone Micro Molding
We are committed to making that which is apparently impossible possible.
Thanks to the latest technologies, our own mold making facility and the strictest quality control, we create products that set standards in terms of functionality, design and efficiency.
Micro-silicone components lighter than 10 mg
Silicone micro molding is a specialized manufacturing process employed to produce extremely small precision silicone components. It is a further development of the classic injection molding process where the focus is on the processing of silicone in microscopic dimensions. We at starlim are capable of manufacturing micro-silicone components weighing less than 10 mg with precision undercuts and indentations. The smallest component manufactured to date by starlim for the medical sector only weighed 0.00049 g. It is difficult to find a comparison that matches this. 0.0005g is roughly equivalent to the weight of two grains of salt or the wings of a fruit fly. We are convinced that even smaller components can be created.
Our expertise in the area of silicone micro molding was already highlighted in 2014, and you can read more about this in the article “Die große Kunst der kleinen Teile” (The Enormous Challenge of Tiny Parts).
Silicone micro molding component categories
Silicone micro molding is a key technology of the future, particularly in a world in which miniaturization and precision are increasingly important. The combination of a state-of-the-art production process with the unique properties of silicone opens up unparalleled opportunities which cannot be realized in traditional manufacturing processes.
Micro injection molding at starlim enables the production of extremely small, high-precision components for sophisticated applications in medical technology, microelectronics and the mobility sector. We employ the latest production technology to produce microstructured components, ultralight microform parts in the milligram range and micro-precision molded parts with tolerances in the µm range.
Each of these component classes offers unique advantages and application options. We will clarify the specific properties and applications for which these high-precision injection moldings are employed below.
Microstructured injection moldings
Injection moldings with microstructured features are plastic or silicone components manufactured through the injection molding process and exhibit precisely defined microstructures. These microstructures can constitute mechanical, optical or functional characteristics. You can discover various microstructures on our sample plates.
Weight in the milligram range
Micro injection moldings or microform parts are extremely small injection moldings with a weight in the milligram range. They are manufactured with high-precision molds and special micro injection molding machinery to ensure minimum tolerances and the finest details.
Tolerances and minimum dimensions in the µ range
Micro-precision molded parts are high-precision injection moldings with extremely fine tolerances and minute dimensions in the micrometer range (µm). These parts are required for applications in which minimum deviations can impair functionality, examples being in medical technology, micro-optics or electronics.
Silicone micro molding: from the initial idea to series production
Development of a high-precision microform part requires expertise, the latest technologies and a structured process. We support you with our micro injection molding from the initial idea through the prototype phase and on to series production. Together, we develop tailored solutions that meet the highest requirements in terms of precision, functionality and efficiency. You can access further information here on our services in the area of product development.
Our proven development process ensures that your individual requirements are implemented to an optimum degree. We clarify the individual steps involved below, from the concept phase to series production.
Solving problems and finding a common approach
We are your partner when it comes to solving problems and developing products. Our customers benefit from our years of know-how and the size of our enterprise. We cooperate with you to develop products that meet your requirements, monitoring the entire process as we do so. Production of your silicone part is not our only goal. Our aim is to understand your needs, further developing the product together with you and ensuring in the production process itself that the molded parts can be processed further with ease in the subsequent process.
Success in our eyes is our ability to familiarize ourselves with your requirements and understand your product.
Prototype construction and perfection of our micro components
starlim bundles all the required know-how – and you profit from this! Our in-house mold making facility enables us to directly implement customer requirements and further optimize the mold for series production. We understand your product, consider the application case and build on this knowledge to construct our injection mold. Our own micro molding production facility combines knowledge from mold construction, machinery development and automation to ensure a reliable production process, ensuring and guaranteeing uniform part quality as a consequence, even during mass production. starlim also enables the
Together, we achieve optimum results, regardless of the scope of the challenge we face.
Series production, quality and packaging
Our expertise encompasses both single and multi-component injection molding processes, supported by the latest handling robots for efficient removal of parts. Optical quality monitoring during the production process enables us to ensure that each component meets the highest standards. In addition, we also enable the targeted depositing of parts and automated component packaging. We can also realize production under cleanroom conditions if desired, thus ensuring a maximum level of hygiene standards. We achieve all of this while observing the strictest quality measures which are continuously monitored by our extensive quality management.
We stand for uncompromising quality in series production, due to our use of state-of-the-art injection molding technology.
Frequently asked questions
How “light” can a starlim micro molding component be?
The smallest component manufactured to date by starlim for the medical sector only weighed 0.00049 g. It is difficult to find a comparison that matches this. 0.0005g is roughly equivalent to the weight of two grains of salt or the wings of a fruit fly. We are convinced that even smaller components can be created.
Which wall thicknesses can be achieved?
The wall thickness depends on a variety of factors.
- How is the peripheral area of the thin wall thickness structured?
- What is the area of the wall thickness?
- Which raw material is used?
- Which characteristics should the wall thickness fulfill?
We have already manufactured micro injection moldings with wall thicknesses of 10-15 µm. Through discussion of your needs and joint development, we would be more than happy to address your requirements in detail.
How “small” can a hole be?
Holes in the 0.1 mm range are possible, depending on the length-to-diameter ratio.
How are the finished products measured?
Micro injection moldings with µm tolerances have already been produced and checked at starlim. This requires a high level of accuracy, an enormous effort during testing and an individual approach.
We measure according to weight, using optical measuring instruments or the application of CT. Where micro injection moldings are involved, one frequently reaches the limits of the measuring ranges of different equipment. We offer individual solutions for the measurement of micro injection moldings, including functional tests to adhere to the tolerances defined.
Our aim is to cooperate with you in defining those tolerances necessary for the functioning of micro injection moldings, keeping testing and expenditure costs as low as possible. When it comes to measurement, we can draw on our extensive know-how and, together with you, determine which test methods are required.
Is a cleanroom available?
Yes, our cleanroom is classified according to ISO Class 8 and GMP Class D.
Is the maximum number of mold cavities limited?
The number of mold cavities depends on the quantity, the shot volume and, primarily, the level of complexity and component tolerances.
Therefore, a general answer to this question is unfortunately impossible. In the micro molding area, molds with 1 to 64 cavities have already been designed by starlim. We would be delighted to discuss your micro molding requirements with you and, together, to determine how the mold should be constructed.
Which removal and packaging concepts for parts are available at starlim?
Depending on the batch size and component geometry, we offer flexible removal and packaging solutions ranging from manual demolding to fully automated depositing in the packaging. Integrated camera inspection ensures that the quality of micro injection moldings meets the highest of standards and flawless further processing in subsequent production steps is assured. As a full-service provider, we develop and produce tailored automated solutions which are optimally aligned with your requirements.
Which materials are processed?
All liquid silicones and thermoplastics can be processed. Insert components can also be created with other materials, including metal, glass or ceramics.
Find out more about what we have to offer here.
Which services does starlim provide in the area of micro molding?
We can implement everything, beginning with design proposals, continuing with FE analyses, material selection and mold development, and including automated production and transport solutions (such as special packaging).
starlim regards itself as a full-service provider and a design partner and are happy to provide support when it comes to questions regarding design and the functionality of micro injection moldings.
Does starlim have its own mold making facility?
sterner manufactures high-precision molds in the in-house mold making facility at the main location of our business complex in Marchtrenk. Micro molding sees our interdisciplinary teams combining comprehensive expertise from design, mold construction, application technology and production – all under a single roof. This synergy creates high-quality, innovative solutions and enables us to react efficiently and flexibly to the requirements of our customers.
What advantages does silicone offer as a material?
Silicone possesses numerous outstanding properties without which the world we know today would be inconceivable. It is resistant to UV and hot water and safe to use with potable water. Thanks to a high degree of ductility, elasticity, tensile strength and frost resistance, it is suitable for numerous areas of use, particularly in the industrial sector and medical technology. In addition, it is an excellent material for use in process-controlled manufacturing processes.
For the smallest mold and maximum precision – just call us!
We look forward to hearing from you and the opportunity to discuss your product ideas with you! Please arrange an appointment with us today – naturally with no commitment on your part. We would be happy to send you further information and product samples if requested.
Your contact person
Matthias Pfeil
Business Development Micro Molding
Mail: Matthias.Pfeil[at]starlim[dot]com
Starlim Spritzguss GmbH
Muehlstraße 21
4614 Marchtrenk
Austria
Tel.: +43(0) 7243 58596-0
