Injection Molded Parts
Injection molded parts are created using molten polymer or thermoplastics and sometimes using glass or metal additives. In this forming process, molten material is injected into a mold, and once cooling takes place, the material assumes the desired shape.
MW Components' East Providence facility produces many products for various industries and applications, including plastic optics, biomedical products designed for implantation, and others. These parts are produced using one or more forms of injection molding or medical molding, including micro molding, overmolding, and insert molding. Our engineers are equipped with the latest, state-of-the-art Autodesk® Moldflow software to analyze filled or unfilled resin flow patterns in the most sophisticated micro-part designs, as well as SolidWorks CAD software to handle the most demanding design needs that your project requires. We even offer 3D prototype printing on-site using our FDM 3D printer. Whether your concern is design for manufacturability, difficult-to-process resins, or complex part geometries, we have the knowledge, experience, and team of experts to make the parts you need.
Custom Manufacturing
Custom Injection Molding
Our design and engineering experts routinely work with customers to develop custom injection molding solutions fit for unique applications and use cases, including custom components for medical, automotive, and aerospace. We have also found success replacing glass with plastic for optical purposes, which significantly reduces material costs for our customers. Our experts offer decades of engineering experience for a variety of applications as well as key knowledge to ensure design for manufacturability.
In addition to industry and application experience, our teams have an extensive track record utilizing custom materials that are tailored for our customer’s property-intensive applications. These include biomaterials like bioresobable polymers, metal replacement polymers, and custom compounded resin with fillers like barium sulfate, bismuth trioxide, fire retardants, and lubricants.
Injection Molded Parts Manufacturing
Our team of skilled micro molding and injection molding experts offers efficient and effective polymer molding along with a detailed QA process that ensures performance. Our list of injection molding capabilities is vast and includes micro molding, micron tolerance molding, insert molding and overmolding.
In addition to manufacturing, QA, and analysis testing, MW Components offers several other value-added services, including prototyping, vendor-managed inventory, as well as component sourcing and supply.
Micro Molding
MW Components produces custom plastic components and assemblies using highly precise techniques for demanding micro-molding challenges.
Manufacturing small requires the ability to measure to the smallest degree. Micro-sized shifts are detected and accounted for so that all the parts that pass through our facilities reach the same rigorous quality standards from the first part to a part made on the millionth run. We are known for our precision and consistent quality no matter your requirements or run size.
Micro Molding Capabilities & Tolerances:
- Ø130 micron microfluidic orifices held to +/-3.75 microns
- Microfluidic channels as shallow as 30 microns
- Cleanroom molded microlens center to center true position accuracy to 5 microns
- 1.6mm posts w/undercut held to <+/-13 microns on dental components (No parting line)
- Complex micro-sized features on critical drug delivery device components
- Textured 3-dimensional microfluidic features for medical diagnostic devices
Ready to get started? Request a quote to send us your specs or request further details.
Insert Molding & Overmolding
We have served many Fortune 500 companies over the years to deliver efficient automated insert molding cells to produce a variety of products including connectors, impellers, and stators. These cells integrate process control sensors to ensure the highest quality and are designed for maximum up-time.
Ready to get started? Request a quote to send us your specs or request further details.
Micron Tolerance Molding
We have established a solid, performance-based reputation for molding micron-tolerance components. Using proprietary mold-making processes, we routinely produce parts to the following specifications:
- Lens surface finishes within 1/4 – 1/2 wavelength
- Hole diameters as small as 230μm in thin walls
- Concentricity of coaxial features within 10μm
- Small hole diameters to under 4μm
- Small hole centerline distances held within 1μm @ 250μm pitch, non-cumulative over a ten pitch length
- Flatness of mirror surfaces within 10μm
Specific competencies include:
- Integrated lens molding
- Microlens array molding
- Fiber alignment (V) groove molding
Ready to get started? Request a quote to send us your specs or request further details.
Related Manufacturing Services
In addition to design for manufacturability and advanced manufacturing, we offer expertise in specialty services.
Thermoplastics & Injection Molding Polymers
Injection molded parts are made from a range of thermoplastics and polymers. MW Components specializes in working with high-quality polymers.
- Acetal (POM)
- Acrylonitrile Butadiene Styrene (ABS)
- Liquid Crystal Polymer (LCP)
- Nylon (PA)
- Polybutylene Terephthalate (PBT)
- Polyetheretherketone (PEEK)
- Polyphthalamide (PPA)
- Polypropylene (PP)
- Polystyrene (PS)
- Ultem® (PEI)
- Others
Have Questions?
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