Micro-injection Moulding

Technology Machines Markets

2
Identify potentials, exploit market opportunities
Advantages of Demag machines for
micro-injection moulding
Flexible: A modular machine range that meets the needs of
micro-injection moulding
Adaptable: A wide variety of other applications can be implemen-
ted by changing barrels on a standard machine
Economical: Low-cost standard pellets can be used by means of a
14 mm special-purpose screw
Precise: Extremely high precision through ultra-sonic stroke-
measuring systems
Safe: Active mould protection with even the smallest mouldings
MICRO-INJECTION MOULDING
Small, smaller, extremely small miniaturisa-
tion is on the advance everywhere. Whether
electronic equipment or mechanical aids, the
trend is towards compacting an ever increa-
sing number and more complex functions in a
minimum of space. Consequently, there is an
increasing demand for small and minute micro-
scale components often weighing only a few
milligrams.
Micro-technology and micro-systems
are growth markets
Competence in micro-injection moulding tech-
nology opens up the door to a wide variety of
markets that are marked by dynamic and sus-
tained growth. Major applications include such
elds as sensors, optical or electronic systems.
Products from these areas are in turn used in
numerous other industries, such as medical de-
vices, biotechnology, in products for telecommu-
nications and IT periphery and, last but not least,
in automobiles. The latter may have as many as
170 actuators and up to a 100 sensors installed
that are based on micro-system technology. In-
creasing miniaturisation and function integration
will provide opportunities for two-digit growth
rates for micro-systems in the next few years.
With this in mind, Demag Plastics Group has
developed what is a specialist injection unit in
its own right to meet the requirements of mi-
cromoulding: the micro-shot unit with a 14 mm
special-purpose screw. Moreover, micromould-
ing calls for a holistic approach to the process.
Only an optimum interplay of the machine,
mould, material, periphery and know-how will
warrant high-quality production.
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Micro-system technology a growth market
2002 2003 2004 2005 2006 2007 2008 2009 2010
70
60
50
40
30
20
10
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US $ 50 billion
US $ 3,9 billion
US $ 8,3 billion
US $ 68 billion
US $ 200 billion
Market volume
Micro-systems
MEMS components
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Holistic approach to production
Inevitably, the manufacture of such small
precision parts poses a special challenge, and
perfect orchestration of the production systems
is of primary concern. The very tiny scale of
the components gives an idea of the difcult re-
quirements to be met. Mouldings weighing no
more than a few milligrams will require a dif-
ferent production environment than normal
plastic parts, if only for physical reasons. It
follows that everything, the injection moulding
machine, the mould and the peripheral equip-
ment including parts removal and temperature
control systems as well as the process itself
must be tailored to the needs of micromould-
ing. Obviously, cost efcient solutions are
called for that will provide a consistent level of
quality in high-volume commercial production.
Standard pellets keep costs at
competitive level
Plastics for micro-injection moulding must pos-
sess all function-dependent, moulding-specic
properties. In addition, there are production-
specic requirements to be met, such as
Good ow ability in order to enable cavities
to be lled at low cavity pressures and exactly
duplicated
Mixing of additives (antistatics, lubricants)
should be possible
Freedom from particles and high charge-to-
charge homogeneity to avoid rejects
Freedom from evaporation to prevent depo-
sits on ne textures of the cavities
The ability to use standard plastics is, of course,
a desirable goal. Especially as special micro-
pellets tend to be many times more expensive
than comparable standard pellets. On the other
hand, a fact to be considered is that there are
individual applications where the size of a
micro-part may be no greater than that of an
individual granule.
Demags concept: Flexible and modular
In the case of micro-injection moulding, Demag Plastics Group relies on
a combination of quality, efciency, exibility and cost-effective produc-
tion. Its competence in this eld is the outcome of more than 10 years
experience in micro-moulding. Every year the company puts on stream
some 40 machines specially for micro-injection moulding.
Demag Plastics Group`s concept for micromoulding is based on modied
standard machines with capacities up to 500 kN that are equipped with a
special micromoulding unit. The combination of a standard machine and
a micro-shot unit with a 14 mm special-purpose screw offers a maximum
of exibility and economy and permits high-grade micro-mouldings of a
few thousand grams to be moulded with shot weights of 0.1 to 0.5 g.
This Demag concept makes it possible for processors to launch out into
micromoulding with moderate initial costs. Instead of investing in an
expensive specialised machine, its customers can cost-effectively con-
gure their machine from Demags modular machine range to t their
specic needs.
Our range includes hydraulic or all-electric drives as well as various
clamping units to suit the specic application. Generously dimensioned
tiebar clearances permit both the installation of large multi-cavity or
hot-runner moulds and upgrading of moulding capability with automa-
tion and accessory equipment.
Long opening strokes permit the use of robot systems with complex
tasks. Also, specialised solutions are conceivable, say, micro-injection
moulding using two-component technique.
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The basis of any micromoulding production is rst of all a suitable
machine. Demag Plastics Groups philosophy is to use standard machines
with hydraulic drive and clamping forces of 250, 350 or all-electric
machines with 500 kN clamping force. Of course, the plasticising unit
must be compatible with the small shot weights. For, if the residence
time of the melt in the screw barrel is too long, there is the risk of
thermal degradation of the material.
Microshot: Flexible and economical
Depending on the machine concept, Demag
Plastics Group offers two systems:
Hydraulic injection moulding machines
featuring a highly dynamic Smart pump with
pressure and ow control.
All-electric machines equipped with high-
torque direct drives.
Mould technology and mould protection
Same as the injection moulding machine, it is
necessary that the injection mould should meet
the special requirements of micro parts. Moulds
are required to be fabricated to a very high
standard of workmanship. In addition to estab-
lished machining processes, such as micro-
grinding, micro-milling or micro-drilling and
boring, completely new processes are required
for the ne details and geometries.
INJECTION-MOULDING TECHNOLOGY
Typical methods are micro-EDM, electro dis-
charge machining, the LIGA process (litho-
graphics, galvanoforming, replication) or laser
machining.
Thin drilled holes in the moulding can some-
times only be produced as blind holes. There-
fore, mould venting is of special importance.
Especially in the case of cold runner moulds, it
is necessary to allow a relatively large amount
of air to escape while ash-free sealing is
required on small areas.
Protection of the small, vulnerable moulds for
micro-parts needs special attention. Active and
sensitive mould protection is an absolute neces-
sity. A sensor detects the force required for the
clamping motion and compares it with a stored
master curve. If any deviations exist, the closing
operation is actively braked by the drive of the
Performance data:
Injection unit: 25
Screw diameter: 14 mm
Screw geometry: Special geometry
Shot weight: 0.1 1.5 g
Injection pressure: 2,700 bar
Minimum mould height: 110 mm (smaller, if desired)
The Microshot unit on a 250 kN machine
Integrated illumination of mould space (optional) facilitates visual supervision of
micromoulding
The Microshot injection unit for low-cost
standard pellets
For micro-injection moulding, Demag Plastics
Group ts its machine with a size 35 or size
45 Microshot injection unit. The plasticising
barrel of these machines can be changed in less
than 15 minutes to convert the machine from a
standard unit into a Microshot unit.
Of special importance with low shot weights,
very short injection strokes and sometimes very
short injection times is precise, high-resolution
and rapid-response control of injection and
holding pressure.
The eld-proven 14 mm three-section screw (L/D = 20) typically has a recommended
shot weight range of 0.1 to 2 g and provides excellent feed performance for standard
pellets and very good homogenisation performance.
Various applications with shot weights of less than 0.1 g even show extremely high
degrees of repeatability of less than 1 % weight scatter.
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Mould protection function with a separate control page
clamping unit. Mould protection can be armed
over the full closing movement. This will not
affect the speed setting.
Integration of micromoulding in controller
Decient venting in lling the mould is liable
to cause compression and heating of the air
entrapped causing blemishes and charring on
the part. Therefore, venting of the cavity at the
end of the ow path requires special attention
in the case of micro parts. Effective remedies
are a stepped clamping force build-up and the
option of evacuating the mould by a vacuum
pump. Both functions are provided and sup-
ported by the control system of the Demag
machines. In order to better replicate ligree
surface details, it is good practice to start the
cooling phase only during the hold pressure
phase. To this end, the temperature control
media are changed from hot to cold only after
injection. This feature, too, is incorporated in
the control system.
10 mm
1.5 g*
*referred to 14 mm screw, PA 6
The stroke-measuring systems provide fast and precise action. The ultrasonic stroke-
measuring system has a resolution at a level of 0.01 e in real time. The all-electric
machine is equipped with incremental measurement for a resolution of under 0.001 mm
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It is accepted that the peripheral equipment,
too, should be matched to the specic needs of
micro-injection moulding.
Problems may be encountered, for instance, in
demoulding micro parts. This must take place
precisely in order to prevent any damage to
core and cavity. Because the ejector pins used
in micro-technology are very thin, 0.2 mm dia
being by no means rare, the ma chine ejector
must respond very sensitively and accurately.
Controlled removal and depositing of the
moulded parts is provided by parts handling
systems whose grippers are designed to match
these specic conditions or which demould
and deposit the micromouldings by means of
vacuum.
Free-fall demoulding of micro parts frequently
fails due to static charging. Either the parts spill
Functionality around Microshot
uncontrolled in all directions or they stick to
the cavity wall or oat in the mould space.
Demoulding problems of this kind can be
overcome by the use of ionised air. In special
cases, it is necessary to carry out production
under cleanroom conditions. Depending on the
particular application, a top-mounted Laminar
ow box may be sufcient. It also offers an
advantage in that the ionised air counteracts
static charging of the moulded parts.
In selecting the equipment for material prepa-
ration, both drying and delivery, it is necessary
to make special allowance for the low material
feed rates. Generally, drying of the material
directly on the machine is recommended. The
size of the material hoppers has to be selected
to suit the small feed rates in order to prevent
overdrying or thermal degradation. Alterna-
PERIPHERAL TECHNOLOGY
tively, ll level control or controlled dry air
admission may be provided.
The small shot weights are critical in selecting
suitable colorant feed systems. Irrespective
of whether liquid colorant, pigment powder
or master batch has to be fed, high-precision
systems are the order of the day. Sometimes,
the use of mixing nozzles may be necessary for
better pigment dispersion.
Parts removal robots
may in the classic ver-
sion enter the mould
opening from the top or
be designed for lateral
removal. Monitoring of
parts removal may be by
integrated supervisory
systems that operate with
optical assistance


Laminar ow box above the mould space
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Backed by many years experience, Demag
Plastics Group has successfully tackled widely
different tasks in micro-injection moulding
together with its customers relying on its
concept of a standard machine combined with
the microshot injection unit.
Like in conventional injection moulding, multi-
cavity moulds also offer economical and tech-
nical advantages in micro-injection moulding.
With greater mastery of the peculiarities of mi-
cro-injection moulding, the trend is towards the
increasing use of multi-cavity moulds.
Aside from standard injection moulding at the
micro scale, there has been strong interest in
special processes, such as two-component
technology. Micro parts can be provided, for in-
stance, with a sealing function by injecting a
exible component.
Microshot solutions in practice
2-component micro valve seat
4-cavity-mould, core back technique
Material: Rigid component
PP + 30% GF
exible component
TPE
Shot weight of both components:
3.4 g
Part weight: 0.054 g
Machine: Demag Multi
50/370-35h/35w
Special features: Extremely high preci-
sion and dimensional
accuracy required
Micro gearwheel
16-cavity sliding split mould
Material: POM
Shot weight: 0.16 g
Part weight: 0.0009 g
Machine: Demag Concept
25/280-35
Special features: Extremely high
precision and
dimensional accuracy
requirements, cavity
oriented, high-speed
removal, cycle time
under 6 seconds
Medical devices
Single-cavity mould
Material: PP
Shot weight: 0.31 g
Part weight: 0.001 g
Machine: Demag IntElect
50/330-45
Special features: Extremely high preci-
sion and dimensional
accuracy required
Activating pin
48-cavity mould
Material: ABS
Shot weight: 1.72 g
Part weight: 0.007 g
Machine: Demag System
25/280-35
Special features: Extremely high preci-
sion and dimensional
accuracy required
Spool lever
4-cavity-mould
Material: ABS
Shot weight: 0.23 g
Part weight: 0.057 g
Machine: Demag System
25/280-35
Special features: Hot-runner direct
injection
APPLICATIONS
www.dpg.com
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Asia
Demag (Malaysia) Sdn Bhd
15-E, 5th Floor, Block 1
Worldwide Business Park
Jalan 13/50, Section 13
40000 Shah Alam
Selangor Darul Ehsan, Malaysia
Tel.: +60-3-55 12 97 40
Fax: +60-3-55 12 97 60
E-Mail: dpa@demag.com.my
Brazil
Demag Ergotech Brasil Ltda.
Av. Ceci, 608 Galpao B11
Tambor
06460-120 Barueri (SP)
Tel.: +55-11-41 95-41 12
Fax: +55-11-41 95-41 13
E-Mail: brasil@demag-ergotech.com.br
China
Demag Plastics Machinery (Ningbo) Co., Ltd.
No.669, Kunlunshan Road, Beilun District,
Ningbo, 315800, Zhejiang Province, P.R.China
Tel.: +86-5 74-86 18 15 00
Fax: +86-5 74-86 18 15 18
E-Mail: sales.cn@dpg.com
China
Demag Ergotech GmbH
Shanghai Rep. Ofce
6F, No. 1221, Hami Road,
Shanghai 200335, China
Tel.: +86-21-52 19 50 00
Fax: +86-21-52 19 62 50
E-Mail: shanghai@demag-ergotech.com.cn
CIS
Mannesmann Demag Plastservice
Prombaza OAO Stroitransgaz
d.Ascherino
Leninskiy raion
142717 Moscow region
Tel.: +74-95-9 37 97 64
Fax: +74-95-9 33 00 78
E-Mail: info.plastservice@dpg.com
France
Demag Ergotech France sas
Zac du Mandinet
9, rue des Campanules
77185 Lognes
Tel.: +33-1-60 33 20 10
Fax: +33-1-60 06 28 89
E-Mail: detf@dpg.com
Germany
Demag Ergotech GmbH
Werk Schwaig
Altdorfer Str. 15
90571 Schwaig
Tel.: +49-9 11-50 61-0
Fax: +49-9 11-50 61-2 65
E-Mail: info-dpde@dpg.com
Germany
Demag Ergotech GmbH
Werk Wiehe
Donndorfer Str. 3
06571 Wiehe
Tel.: +49-3 46 72-97-0
Fax: +49-3 46 72-97-333
E-Mail: info-dpde@dpg.com
India
L&T-Demag Plastics Machinery Limited
Mount-Poonamallee Road
Manapakkam/Chennai 600 089
Tel.: +91-44-22 49-04 32
Fax: +91-44-22 49-49 52
E-Mail: nss@Itdemag.com
Italy
Demag Plastics Group Italia s.r.l.
Via Bassano 3
03012 Anagni (FR)
Tel.: +39-07 75-77 20 04
Fax: +39-07 75-77 20 04
E-Mail: lido.ghirlandini@dpg.com
Poland
Demag Plastics Group Sp. z o.o.
ul. Jagiellon ska 81-83
42-200 Cz estochowa
Tel.: +48-34-3 70 95 40
Fax: +48-34-3 70 94 86
E-Mail: info@demag.pl
Spain
Demag Ergotech Espaa, S.L.
Pol. Ind. Can Caldern
Avd. Riera de Fonollar
Esquina C/Murcia, n37-A, Nave F
08830 Sant Boi de Llobregat (Barcelona)
Tel.: +34-93-6 52 95 30
Fax: +34-93-6 54 78 10
E-Mail: angel.lozano@dpg.com
United Kingdom
Demag Hamilton Ltd.
Hamilton House, Broadelds
Bicester Road, Aylesbury
Bucks, HP19 8AY
Tel.: +44-12 96-31 82 00
Fax: +44-12 96-42 62 22
E-Mail: salesUK@dpg.com
USA
Demag Plastics Group Corp.
11792 Alameda Drive
Strongsville, Ohio 44149-3011
Tel.: +1-4 40-8 76-89 48
Fax: +1-4 40-8 76-64 39
E-Mail: info-dc@dpg.com
Many moulders today operate three shifts, some on 365 days of the
year this calls for a maximum of availability of the machines, spare
parts, and service support.
Backed by highly skilled service teams, advanced spare parts logistics, and
multiple service levels to address a customers specic needs, we provide
total support world-wide: from straightforward inspections through com-
prehensive maintenance, and extended warranties for high capacity
utilisation levels to emergency hotline support, and training of your
personnel.
Full documentation and a digital catalogue ensure that spare parts are
delivered to you in a minimum of time, usually within a few hours. Users
of older machines can have them upgraded by our retrot service at fair
prices, for instance, by state-of-the-art control software or for specialised
injection-moulding processes. In short, the Demag Service provides you
with whatever support you need to complete your jobs efciently and
to schedule.
The responsibility to ensure that everything
runs smoothly