Injection Molding Services
Prototype aluminum tools and production steel tools for low and mid-volume runs — first articles in 10 weeks, production parts in 12 days
Microns Hub's injection molding service covers prototype aluminum tools for small-batch runs, production steel tools for mid- and high-volume parts, and the full range of engineering thermoplastics — ABS, PC, PP, PE, POM, PA6/PA66, TPE, TPU, and more. Overmolding and insert molding are available on request. First articles ship 10 weeks from tool kickoff; production parts then ship in 12 working days. Every project includes a full DFM review with draft-angle analysis, parting line optimization, and gate-location recommendations from an assigned engineer before tooling begins.
Capabilities
- Prototype aluminum tooling — Fast, cost-effective aluminum molds for 100–10,000-part runs; ideal for functional testing and market validation.
- Production steel tooling — Hardened steel tools for high-volume, long-life production; amortized across hundreds of thousands of parts.
- Thermoplastic resin selection — Access to the full range of engineering thermoplastics: ABS, PC, PC/ABS, PP, PE, POM, PA6/PA66, TPE, TPU, PMMA, and specialty resins on request.
- Overmolding — Two-shot and insert overmolding — soft-touch grips on rigid handles, TPE seals on plastic housings, elastomer bonded to metal inserts.
- Insert molding — Threaded brass inserts, metal shafts, and electrical contacts embedded during molding.
- Tolerance ISO 20457 / DIN 16742 — Standard injection molding tolerances per European resin-specific standards; tighter tolerances on critical features via mold design.
- DFM with draft-angle analysis — Every project gets a full DFM report covering draft angles, parting line, gate location, ejector pin placement, wall uniformity, and shrinkage.
- Material traceability — Resin certificates of analysis and batch traceability on request at no extra charge.
- Secondary operations integrated — Assembly, pad printing, ultrasonic welding, and mechanical finishing coordinated through the same quote.
- Prototype-to-production continuity — Start with a prototype aluminum tool for market validation, then transition to a production steel tool — same resin, same design, same supplier.
Materials
| Material | Grade | Properties | Common Uses |
|---|---|---|---|
| ABS | general-purpose and fire-retardant grades | Tough, good surface finish, easy to mold | Consumer housings, electronic enclosures, appliances |
| Polycarbonate (PC) | clear, opaque, fire-retardant | High impact resistance, transparent options, high heat resistance | Optical parts, safety equipment, demanding housings |
| PC/ABS blend | general-purpose | Toughness of PC with easier processing of ABS | Automotive interior parts, robust consumer housings |
| Polypropylene (PP) | homopolymer, copolymer, GF-reinforced | Low cost, chemical resistance, fatigue resistance (living hinges) | Packaging, caps and closures, living-hinge parts |
| Polyethylene (PE) | HDPE, LDPE, LLDPE | Chemical resistance, flexibility, FDA-compliant grades | Containers, bottles, industrial tanks |
| POM (Acetal / Delrin) | homopolymer and copolymer | Low friction, dimensional stability, fatigue resistance | Gears, bearings, precision mechanical parts |
| Nylon (PA6, PA66) | unfilled and 15–50% GF-reinforced | High strength, wear resistance, good chemical resistance | Structural brackets, automotive parts, industrial components |
| TPE / TPU | various Shore A and Shore D hardnesses | Elastomeric flexibility, good chemical resistance | Seals, gaskets, grips, overmolded soft-touch surfaces |
| PMMA (Acrylic) | general-purpose and impact-modified | Optical clarity, weather resistance, scratch-resistant | Lighting diffusers, displays, cosmetic parts |
Tolerances & Specifications
| Spec | Value | Notes |
|---|---|---|
| General tolerance standard | ISO 20457 / DIN 16742 | European resin-specific standards; varies by polymer and feature |
| Typical dimensional tolerance | ±0.1 to ±0.3 mm | Depends on resin shrinkage, feature size, and gate location |
| Tighter tolerance on critical features | ±0.05 mm | Achievable on feature-specific callouts through mold design and process control |
| Draft angle (standard) | 1.5° minimum | For vertical walls; reduces to 0.5° for textured surfaces (adjust accordingly) |
| Wall thickness uniformity | ±10% | Critical for avoiding sink marks, warpage, and short shots |
How It Works
- Step 1: CAD upload and DFM review — Upload your STEP file. Your assigned engineer analyzes draft angles, wall thickness, parting line, ejector placement, and gate location — returns a DFM report within 1–2 working days.
- Step 2: Tooling design and quote — Tool design finalized based on DFM feedback. Quote covers tool cost, per-part cost at target volume, and lead times for both first articles and production parts.
- Step 3: Tool manufacturing — Prototype aluminum tools typically manufactured in 6–8 weeks; production steel tools in 8–10 weeks. First-article parts delivered 10 weeks from tool kickoff.
- Step 4: First-article inspection and T1 sampling — T1 samples dimensionally inspected against your drawing; revisions to the tool (if needed) applied at no extra charge within the first inspection round.
- Step 5: Production runs and EU delivery — Once the tool is approved, production parts ship in 12 working days per batch. Pan-EU transit 2–4 working days.
Lead Times
| Tier | Quantity | Working Days |
|---|---|---|
| DFM review + quote | any project | 1–2 working days for DFM, full quote within 3 |
| First articles from tool kickoff | 10–50 T1 sample parts | 10 weeks for prototype aluminum tools |
| Production parts once tool exists | any batch | 12 working days production + 2–4 EU transit |
Applications
- Consumer product housings — ABS and PC/ABS housings for hand-held electronics, appliances, and consumer hardware. Typical batches 1,000–50,000 pieces.
- Industrial and automotive components — PA6/PA66 and glass-filled nylon brackets, clips, and structural parts. Typical batches 500–10,000 pieces.
- Medical device housings and enclosures — PC, ABS, and medical-grade resins for diagnostic equipment and single-use devices; partners with ISO 13485 available.
- Packaging components — PP and PE caps, closures, containers, and fittings for consumer and industrial packaging. Large-volume steel-tool production.
- Overmolded grips and soft-touch parts — TPE over rigid polycarbonate or ABS substrates for tools, handles, and ergonomic grip surfaces.
- Small structural and functional parts — POM (Delrin) gears, bushings, and precision functional parts requiring dimensional stability and low friction.
Why Microns Hub
- Prototype-to-production continuity in one supplier — Start with a prototype aluminum tool for market validation, then move to a production steel tool with the same supplier and same part design — avoiding the translation loss that happens when tooling and production are split across vendors.
- DFM review before tool cutting — Your assigned engineer reviews draft angles, parting line, and gate location before the tool is cut. Mistakes caught in CAD cost hours; mistakes caught after tooling cost thousands.
- Free resin certificates and batch traceability — Resin certificates of analysis and batch traceability are included free on request — not billed as a line item like most marketplace competitors.
Frequently Asked Questions
How much does an injection mold cost?
Prototype aluminum tools start at a fraction of production-tool cost and are ideal for 100–10,000-piece runs. Production steel tools cost substantially more but amortize across hundreds of thousands of parts with longer tool life. Exact pricing depends on part complexity, cavity count, resin, and expected volume — upload your CAD and we will return a tool quote plus per-part cost at your target volume within 1–2 working days.
What's the lead time for injection molded parts?
First articles (T1 samples) are delivered 10 weeks after tool kickoff. Once the tool is approved, production parts ship in 12 working days per batch plus 2–4 working days of pan-European transit. If your program has a tighter timeline, a prototype aluminum tool is typically 1–2 weeks faster to first article than a production steel tool. The DFM review and quote itself takes 1–2 working days.
What's the minimum order quantity?
Economically, injection molding makes sense when you need 500+ pieces of the same part, because the tooling cost needs to amortize. For smaller quantities, 3D printing (SLS PA12) or CNC machining are usually more cost-effective — and we will tell you this honestly if you upload a CAD with a low quantity. For true production runs above 1,000 pieces, injection molding almost always wins on per-part cost and part consistency.
What resins do you offer?
The full engineering thermoplastic range: ABS (including fire-retardant grades), PC, PC/ABS, PP, PE, POM, PA6/PA66 (unfilled and glass-filled), TPE, TPU, and PMMA. Specialty resins — medical-grade, food-contact, UL-listed — available on request. Tell us your application at quote stage and we will recommend a resin grade that balances performance, cost, and moldability.
Do you offer overmolding and insert molding?
Yes, on request. Overmolding — TPE soft-touch grips on rigid PC substrates, or elastomer seals bonded to plastic housings — is a common option for consumer product parts. Insert molding — threaded brass inserts, metal shafts, electrical contacts — is available when your part needs a metal-to-plastic bond. Both add tool complexity and cost; we will estimate at quote stage.
What DFM support do you offer before tooling?
A full DFM review by an assigned mechanical engineer before any tool is cut. Review covers draft angles (1.5° minimum on untextured walls), wall thickness uniformity (±10% of nominal), parting line placement, gate location, ejector pin placement, and shrinkage calculation for the chosen resin. DFM feedback is returned within 1–2 working days. Tool revisions within the first inspection round are covered at no extra charge.
What certifications are available?
Our network holds ISO 9001:2015 certification by default. Partners with ISO 13485 for medical devices and IATF 16949 for automotive are assigned when your application requires it. Resin certificates of analysis and batch traceability are available on request at no extra charge. Material traceability and First Article Inspection reports are standard for regulated applications.
Related Services
-
3D Printing
For quantities below 500 pieces, SLS PA12 often beats injection molding economically — no tooling cost.
-
Rapid Prototyping
For fit-and-function prototypes before committing to an injection tool — vacuum casting is particularly useful for 10–50-piece test runs.
-
CNC Machining
For prototype parts in the exact production resin (POM, PEEK, ABS bar stock) before a tool is made.
MICRONS HUB DV Ε.Ε. · VAT: EL803129638 · GEMI: 190254227000 · Industrial Area, Street B, Number 4, 71601 Heraklion, Crete, Greece