Covestro Strengthens Sustainability And Competitiveness Of TDI Production

• Double-digit million investment in TDI plant in Dormagen
• Measures further improve energy efficiency and CO₂ footprint
• Consistent alignment of production with customer needs

To further strengthen the sustainability and competitiveness of TDI (toluene diisocyanate) production for the manufacture of flexible foams in Europe, Covestro is investing a mid to high double-digit million euro amount in the modernization of its production plant in Dormagen by 2025. The plant was commissioned in early 2015 and is considered one of the most advanced TDI production facilities in the world due to the use of the gas phase technology developed by Covestro. The work will include the installation of a modern reactor that will enable the reaction energy to be used for energy-efficient steam generation in the future.

The modernisation will significantly improve the plant’s energy efficiency and thereby reduce CO₂ emissions. After the modernization, the plant will consume up to 80 percent less energy than conventional processes for the production of TDI, and greenhouse gas emissions will be reduced by a further 22,000 tons per year. This not only makes a significant contribution to achieving the company’s climate targets and safeguarding European TDI production in the face of sharply increased energy costs, but also improves the sustainability performance of the customer industries. The first phase of the project has now been successfully completed with the lifting of the equipment into the plant. All further measures will be implemented gradually until spring 2025. This will ensure a continuous supply of TDI to customers.

“We want to continue to grow in Germany and drive forward the transformation to climate-neutral production. Nevertheless, the general conditions, especially the high energy prices, are making it increasingly difficult for us to make such investments,” says Dr. Thorsten Dreier, Member of the Board of Management and Chief Technology Officer at Covestro. “Policy-makers must finally take effective measures to restore Germany’s competitiveness in terms of energy prices and ensure a reliable basis for the climate-neutral transformation of industry.”

 Dormagen as TDI Hub in Europe

The TDI plant in Dormagen has an annual capacity of 300,000 tons. It uses the gas phase technology developed by Covestro, which even before modernization required up to 60 percent less energy and up to 80 percent less solvent than conventional processes. The current investment will significantly increase the efficiency and therefore sustainability of the plant even further. TDI is an important raw material for soft foams, which provide comfort in mattresses and upholstered furniture as well as

To further strengthen the sustainability and competitiveness of TDI (toluene diisocyanate) production for the manufacture of flexible foams in Europe, Covestro is investing a mid to high double-digit million euro amount in the modernization of its production plant in Dormagen by 2025. The plant was commissioned in early 2015 and is considered one of the most advanced TDI production facilities in the world due to the use of the gas phase technology developed by Covestro. The work will include the installation of a modern reactor that will enable the reaction energy to be used for energy-efficient steam generation in the future.

The modernisation will significantly improve the plant’s energy efficiency and thereby reduce CO₂ emissions. After the modernization, the plant will consume up to 80 percent less energy than conventional processes for the production of TDI, and greenhouse gas emissions will be reduced by a further 22,000 tons per year. This not only makes a significant contribution to achieving the company’s climate targets and safeguarding European TDI production in the face of sharply increased energy costs, but also improves the sustainability performance of the customer industries. The first phase of the project has now been successfully completed with the lifting of the equipment into the plant. All further measures will be implemented gradually until spring 2025. This will ensure a continuous supply of TDI to customers.

“We want to continue to grow in Germany and drive forward the transformation to climate-neutral production. Nevertheless, the general conditions, especially the high energy prices, are making it increasingly difficult for us to make such investments,” says Dr. Thorsten Dreier, Member of the Board of Management and Chief Technology Officer at Covestro. “Policy-makers must finally take effective measures to restore Germany’s competitiveness in terms of energy prices and ensure a reliable basis for the climate-neutral transformation of industry.”

 Dormagen as TDI hub in Europe

The TDI plant in Dormagen has an annual capacity of 300,000 tons. It uses the gas phase technology developed by Covestro, which even before modernization required up to 60 percent less energy and up to 80 percent less solvent than conventional processes. The current investment will significantly increase the efficiency and therefore sustainability of the plant even further. TDI is an important raw material for soft foams, which provide comfort in mattresses and upholstered furniture as well as car seats, for example. The material will continue to play an important role for Covestro and the processing industries in the future.

“In Dormagen, we maintain the largest production facility for TDI in Europe, which means that the location plays a central role in the reliable supply of our customers in the region. Now we continue to consistently align ourselves with their needs. The investment not only underlines our commitment to the European market, but also enables our customers to further reduce their indirect CO₂ emissions on the way to developing climate-neutral and circular products for the consumer markets,” says Dr. Christine Mendoza-Frohn, Head of Performance Materials Sales EMEA and LATAM. “At the same time, this investment also underlines our ambition to play a leading role in climate protection and the circular economy together with our partners along the value chain.”

As a company, Covestro is completely aligning itself with the circular economy. Along the way, the company has set itself the goal of achieving operational climate neutrality by 2035. Increasing the efficiency of existing production processes is an important lever for this. From 2005 to 2020, Covestro was able to reduce its specific energy consumption – i.e. the energy consumption per ton of product manufactured – by about 35 percent. By 2035, the specific primary energy demand of the three NRW sites is to be further reduced by around 25 percent compared to 2020 through targeted energy management. Covestro aims to save around 1,100 GWh of primary energy per year from 2035. This corresponds to the annual consumption of more than 50,000 average German households.* Within the next five years, almost half of this potential is to be realized.

www.covestro.com

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Alio Industries Stimulates Innovation In Health And Life Science Sectors

ALIO Industries’ ultra-precise motion control systems are indispensable in a variety of health and life science applications due to their unparalleled accuracy, reliability, and repeatability. These systems enable ground-breaking advancements by ensuring meticulous manipulation and positioning, vital for the success of genome sequencing, the manufacture of medical and clinical devices, and digital pathology.

Genome Sequencing. For genome sequencing — where even minor variations in the stage velocity or drift of the trigger clock can cause poor imaging — ALIO is renowned for providing market-leading motion control solutions. The company promotes increased throughput, reduced run time, and lower costs per run coupled with high quality and repeatable imaging by creating a smoother, continuous scan process using a monolithic XY stage and a low friction vertical Z-stage for focusing. Z focusing can compensate for both variation in the sample and the flatness variation of the XY stage. The ideal technology for achieving the optimum move and settle time is a linear motor stage with a magnetic counterbalance. The linear motor allows for maximum acceleration and deceleration and provides exceptional position stability.

Manufacture of Medical and Clinical Devices. Accurate motion control is also crucial in manufacturing medical and clinical devices like diagnostic imaging machines and video endoscopes. For such exacting applications, ALIO provides the Angulares Hybrid Hexapod, which features precision crossed roller bearing guides, optical incremental or absolute encoder feedback on all axes, linear motor and/or servo ball screw drives, unlimited programmable tool center point locations and coordinate offsets, and zero backlash on all axes. This makes the Angulares capable of unlimited XY travel, Z travel of 62 mm (which can be increased to 208 mm using other tripod models); tip/tilt travel of 60 degrees (+/- 30 degrees) with continuous 360 degree Theta-Z; XYZ bidirectional repeatability of less than +/- 100nm; velocity up to 100 mm/second XY and Z; and less than 10 nanometers linear and 0.1 arc-seconds angular minimum incremental motion.

Digital Pathology. ALIO also has a wealth of experience in the area of digital pathology, where the ability to manipulate specimens and imaging devices with unparalleled precision is essential.

Bill Hennessey, President of ALIO says, “ALIO’s motion control systems enable researchers and pathologists to precisely position specimens and imaging components, ensuring accurate and consistent data acquisition. This level of control is particularly critical in applications such as high-resolution scanning, automated sample handling, and image stitching, where sub-micron accuracy is needed. By eliminating motion-induced errors, ALIO’s systems enhance the quality and reliability of digital pathology data, ultimately leading to more accurate diagnoses and accelerating medical research.”

Digital pathology machines demand precise motion control capabilities due to the need for nanometer-level accuracy in specimen scanning and imaging. These systems must precisely position microscope stages and imaging components to ensure that high-resolution images of tissue samples are acquired without motion-induced distortions or artifacts. Any inaccuracies in motion control can compromise the quality of digital slides, potentially leading to misdiagnosis or reduced research validity. Additionally, in automated digital pathology workflows, such as slide loading and sample handling, precise motion control is essential to avoid specimen damage, contamination, or misalignment.

ALIO boasts a range of ultra-precise motion control systems that can cater for even the most demanding digital pathology application.

www.alioindustries.com

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Loacker Recycling: Efficient Cable Recycling with Lindner’s Polaris 2800

Spittal/Drau (Austria), January 2024. Loacker Recycling based in Wonfurt, Germany, is part of the Loacker Recycling GmbH family business headquartered in Götzis, Austria, and specialises in waste cable recycling. Thanks to the recycling concept developed in-house, the company can achieve the highest possible copper recovery at low processing costs. The company trusts in Lindner’s recycling expertise and uses a Polaris 2800 with rotor cooling.

The Loacker Group, based in Götzis, Vorarlberg (Austria), has been dedicated to collecting, sorting and processing valuable materials for over 100 years and is motivated by one thought: The best for the world of tomorrow. Family-owned for five generations, the group consists of a total of 25 companies and operates 47 sites in eight countries. The recycling plant in Wonfurt has been recovering end-of-life cables for decades. These mostly come from the DACH region and are largely collected within the Loacker Group and delivered to Wonfurt for processing. The focus is on extracting pure materials to maximise the recyclables recovery.Matthias Köhler has been Managing Director at the Winford site since 2012. In recent years, a great deal of energy and expertise has been invested in expanding the recycling plant to achieve the best possible recycling results using the latest technology. In a three-shift operation, up to 100 tonnes of end-of-life cables are transformed into valuable recyclable materials every day. ‘We mainly recover copper from old cables, around 40 to 45 tonnes a day, but also PVC and ferrous metals. While the copper is turned into copper sheets in copper smelters, we deliver the PVC to a company located on site. There, the plastics are turned into barrier products. Ferrous metals are sent for metal processing. The way our plant is equipped, we achieve a particularly high degree of purity. That’s what makes us unique and gives us the ability to return almost 100% of the recycled material back into the cycle,’ explains Matthias Köhler.

The Lindner Polaris 2800 with rotor cooling has been part of the plant at Loacker in Wonfurt since July 2023 and shreds copper cables to a final output size of <15 mm. ‘We are more than happy with the throughput rate and are particularly pleased that the shredder handles non-shreddables with ease, which do show up from time to time,’ says Köhler happily. In buying a Polaris, a conscious decision was also made in favour of the screwable and quadruple-use blade cutting system. ‘We change the knives every seven to eight days, which is extremely easy thanks to the screwable system. It is also easy to access the rotor, knives and knife holders,’ says Matthias Köhler.

‘Furthermore, the Polaris 2800 has the necessary drive power. Equipped with a countershaft drive and flywheel energy storage, the machine makes light work of shredding even difficult materials such as end-of-life cables with a high content of copper wire. The consistent throughput rate and high uptimes speak for themselves,’ states Jan Rosenmeyer, Sales Manager at Lindner.

‘We are extremely happy with the Polaris and would choose a Lindner shredder again. Output, rotor cooling and ease of maintenance convinced us. Using a Lindner, you also realise that the company has decades of experience in shredding technology. The overall package is just right,’ adds Köhler.

About Lindner, Spittal an der Drau/Austria | MAKE THE MOST OF WASTE.
The Lindner family business has been offering innovative, tried-and-tested shredding solutions for over 75 years. At its production facilities in Spittal/Drau and Feistritz/Drau in Austria, Lindner manufactures using state-of-the-art production machinery shredders, system components and spare parts that are exported to almost one hundred countries. In addition to stationary and mobile shredders for waste recovery, the portfolio also includes complete systems for plastics recycling, SRF/RDF and waste wood processing. The shredders can be used among other things for municipal solid waste, commercial and industrial waste, waste wood, plastics, packaging material, paper and light scrap. Besides its headquarters in Spittal/Drau and a second production site in Feistritz/Drau, Lindner is also present in Germany, France, the USA and Asia with a total of five sales locations and service hubs.
www.lindner.com

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Am Solutions Brings Exciting 2-In-1 Cleaning And Surface Finishing Machine To Customer Experience Centre

AM Solutions – 3D post processing technology, a pioneering company specializing in post processing technologies for additive manufactured (AM) parts, has just installed its S1 2-in-1 post-processing solution for the cleaning and surface finishing of 3D printed parts in its customer experience centre in Knowsley.

The S1 is a smart solution for cleaning and surface finishing, which set new standards for the post-processing of parts from powder bed fusion (PBF) AM technologies. The smart plug-and-play solution impresses by being able to perform cleaning and surface finishing all in one self-contained unit (the 2-in-1 concept) with the same media, in a manual or automatic process, saving time and costs. Furthermore, it is also suitable for the surface finishing or de-powdered metal components made from non-reactive metals, and is equipped with a blast media conditioning system for optimal and consistent quality of the blasting media. It also features a newly developed air management system which means even fewer deposits in the interior.

Colin Spellacy, Head of Sales at AM Solutions UK says, “As a company operating in the dynamic area of AM post processing, we are focusing increasingly on volume production. The S1 which we have just installed in our customer experience centre is one of our 2-in-1 solutions, running two post processing steps in one single machine. This, combined with a higher degree of automation, streamlines the entire process chain and substantially reduces the costs per piece. Such an approach allows us to perfectly fulfil the requirements of customers who are looking for high volume production with 3D printing technologies.”

Using the S1 system customers can save not only money by not having to invest in additional equipment but also save valuable manufacturing space. Above all, the processing time for 3D printed parts can be reduced by over 60%. The automated S1 technology drastically reduces the need for the manual post-processing of often delicate, large and geometrically complex components which is a necessity for companies using AM for volume manufacturing applications.

Spellacy continues, “We invite anyone interested in our post-processing capabilities to visit our customer experience centre in Knowsley. In the centre we can realistically reproduce and test every likely requirement customers may have when post processing AM parts and components. We can ultimately provide you with details of the perfect process solution for your specific applications. We have several printing technologies and post processing solutions in addition to the S1 in the centre, allowing us to demonstrate the solution that best meets your specific requirements.”

The S1 2-in-1 solution boasts improved basket design for optimal distribution and tumbling of parts, and uses a specially developed wear protection lining made of non-staining anti-static polyurethane. It is also ATEX certified, and has a media conditioning system for maintaining consistent blast media quality and sizing. The systems also uses industry leading process monitoring and visualisation technologies, is Industry 4.0 ready, and has been developed in collaboration with industry leading 3D printing experts.

www.solutions-for-am.com

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XSYS Roundtable Events Gather The German Flexo Industry

Two well-attended regional customer events held in October have been hailed as a great success. Participants from over 50 flexo printing companies came to meet with the XSYS experts and learn about the latest innovations and industry trends.

XSYS is delighted to share the resounding success of two recent customer events in Germany. Designed to inform, engage, and anticipate, the annual flexo roundtables (Flexostammtisch) were first established in 2003. With one ‘Flexostammtisch’ held in the north and one in the south of the country, the events brought together the flexo industry, providing a platform for engaging discussions and knowledge-sharing.

Taking place in Memmingen (Bavaria) on 20 October 2023, ‘Flexostammtisch Süd’ gathered over 40 print professionals, who were welcomed by Markus Mühlfeit, Regional Sales Manager DE/CH. Its northern equivalent, ‘Flexostammtisch Nord’ held in Damme (Lower Saxony) the following week, saw more than 60 attendees greeted by Burkhard Gerken, Regional Technical Sales Manager DE. Both delivered an interesting program of presentations on topical issues, such as sustainability and cost-efficiency in flexo platemaking.

Florian Hölzle, Product Manager nyloflex at XSYS Germany GmbH, gave a compelling talk on optimizing printing with white ink on filmic substrates and corrugated board. After introducing the fully automatic ThermoFlexX Catena+ platemaking line, he went on to outline the benefits of ThermoFlexX Woodpecker surface screening technology. In particular, he discussed the cost-saving potential and improved print quality offered by the recently launched Woodpecker Nevis micro-pattern for white.

Wolfgang Sprehe, Head of the Technical Center at Windmöller & Hölscher, presented the latest findings from a collaborative project with XSYS and the Senne vocational college in Bielefeld. The project has been set up to investigate issues encountered by printers when using PCR (post-consumer recyclate) films on press. Mr. Sprehe emphasized the significant improvements achievable by reducing the ink layer thickness, particularly when using XSYS’ nyloflex FTV 114 D flexo plate in combination with the Woodpecker Nano surface screening pattern.

The days ended with a networking dinner, giving participants ample opportunity to further discuss these important topics and the interesting findings from the industry project.

Reflecting on the success on the events, Burkhard Gerken, Regional Technical Sales Manager DE concluded, “Not only do we use the annual flexo roundtables to share the latest information about XSYS’ innovations and collaborations, but we also gain valuable insights into our customers’ preferences and pain points. It is essential that we understand the challenges they face every day so that we can continue our mission to help them make informed decisions and stay ahead of the competition.”

www.xsysglobal.com

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Innovative Material Solutions For More Forgery-Proof ID Documents

• New passport booklet concepts with high flexibility in design as well as the integration of security features – customized to the required color of passport booklets.
• New polymer solution for passport’s end page.
• Drop-in solution for security features made of Makrofol and Platilon films.

Covestro, one of the leading suppliers of specialty films for identification (ID) documents, is once again setting new standards by pushing the boundaries of innovation in this field. With its commitment to improving the security features that protect modern ID documents from counterfeiting and tampering, the company looks forward to showcasing its latest developments at Trustech 2023 trade fair in Paris, France, from November 28-30.

Covestro offers an extensive portfolio of specialty films that help create excellent, secure ID documents. This includes ID cards and driver’s licenses made from Makrofol ID polycarbonate (PC) films, as well as passports made using Platilon thermoplastic polyurethane (TPU) film materials. Through advanced PC and TPU films, the company develops security feature integration solutions that not only make ID documents highly counterfeit-resistant, but also easy to authenticate.

New horizons in passport booklet security

The industry agrees: Identity documents made of monolithic polymer laminates such as polycarbonate offer increased security against counterfeiting. The foundation for the higher security is multiple features, embedded in various layers of polymer films that are laminated under the influence of heat and pressure in such a way that separation of the layers is impossible without irreparable damage to the document. “We are advancing the concept of multi-layered and laminated security features, from Makrofol polycarbonate data pages to passport covers that use embossed and embedded features to help increase the security level,” says Daniel Hentschel, Global Segment Manager Identification.

As part of its program at Trustech 2023, Covestro is therefore proud to present its new concepts for passport booklets, where Platilon TPU films play a central role by offering passport color, design flexibility and high anti-counterfeiting properties. These Platilon TPU films from Covestro are suitable to produce flexible, wear-resistant passport covers that provide protection for embedded chips and Covestro, one of the leading suppliers of specialty films for identification (ID) documents, is once again setting new standards by pushing the boundaries of innovation in this field. With its commitment to improving the security features that protect modern ID documents from counterfeiting and tampering, the company looks forward to showcasing its latest developments at Trustech 2023 trade fair in Paris, France, from November 28-30.

Covestro offers an extensive portfolio of specialty films that help create excellent, secure ID documents. This includes ID cards and driver’s licenses made from Makrofol^® ID polycarbonate (PC) films, as well as passports made using Platilon thermoplastic polyurethane (TPU) film materials. Through advanced PC and TPU films, the company develops security feature integration solutions that not only make ID documents highly counterfeit-resistant, but also easy to authenticate.

New horizons in passport booklet security

The industry agrees: Identity documents made of monolithic polymer laminates such as polycarbonate offer increased security against counterfeiting. The foundation for the higher security is multiple features, embedded in various layers of polymer films that are laminated under the influence of heat and pressure in such a way that separation of the layers is impossible without irreparable damage to the document. “We are advancing the concept of multi-layered and laminated security features, from Makrofol polycarbonate data pages to passport covers that use embossed and embedded features to help increase the security level,” says Daniel Hentschel, Global Segment Manager Identification.

As part of its program at Trustech 2023, Covestro is therefore proud to present its new concepts for passport booklets, where Platilon TPU films play a central role by offering passport color, design flexibility and high anti-counterfeiting properties. These Platilon TPU films from Covestro are suitable to produce flexible, wear-resistant passport covers that provide protection for embedded chips and antennas. These novel passport covers can be customized with different surface textures and colors.

The presentation of adjacent material solutions around identification documents from Covestro to create security features, hinge connections, as well as passport end page solutions underscores its commitment to the fight against counterfeiting. The result is an integrative ID material concept that is not only safe and durable, but also aesthetically impressive.

Meet us at Trustech 2023

Discover more into cutting-edge and sustainable film material solutions for ID documents by Covestro, we cordially invite you to visit our booth at C067 in Pavilion 5.2. Our experts will be available to provide insights and answers to your questions.

Additionally, Georgios Tziovaras, Global Business Development Manager Identification Documents & Security Printing, will give a talk on ‘Security features in laminated passport book covers’: a presentation on the Innovation Stage on November 28 at 14:30 p.m. CET.

https://www.covestro.com/

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Expansion Of Water Business In Europe: NORMA Group Acquires Italian Company Teco

• Teco offers irrigation solutions for gardening, landscaping and agriculture.
• Acquisition is part of the global expansion of the water business.

Today, NORMA Group signed an agreement to acquire Italian irrigation products provider Teco Srl (“Teco”). Teco specializes in irrigation products for gardening, landscaping and agriculture. The acquisition is scheduled to be completed in early 2024. The parties have agreed to maintain confidentiality regarding the purchase price.

“The acquisition is a crucial step in the global expansion of our water management business,” says NORMA Group CEO Guido Grandi. “With the Teco acquisition, we are expanding our product portfolio and strengthening our development expertise in the European water management sector. Targeted and efficient irrigation of plants in fields as well as irrigation for gardens and public spaces is becoming increasingly important. The periods of drought witnessed in southern Europe in the last years provide striking evidence of this.”

Teco, which is based in Trani in Puglia, has some 20 years of experience in product development and distribution of micro-irrigation solutions. This method of irrigation provides plants with a specific and constant limited amount of water. The company boasts approximately 800 products, including drippers, sprayers, valves and joining elements. Teco’s customers are wholesalers as well as manufacturers of water management systems. In financial year 2022, sales for the company, which was founded in 2004, were approximately EUR 4.7 million.

Samir Shah, President Americas & Water Management at NORMA Group, said: “Through the acquisition, we are gaining additional expertise as well as customers and suppliers in Europe. The Teco acquisition is an important step forward toward realizing our ambitious growth targets for the water management business in Europe. We are committed to developing and delivering our products wherever the demand exists. This approach allows our customers benefit from efficient transport and on-site services.”

NORMA Group generates about a quarter of its sales with water management products. To date, the business is generated primarily in the USA, India, Malaysia and Australia. For the past two years, NORMA Group has maintained a production partnership with an Italian manufacturer of connection technology for drinking water applications. The share of the water business in Europe is expected to grow significantly in the next five years as total sales increase.  

https://www.normagroup.com/corp/en/home/

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Interrogating Your Micro Molding Supplier To Ensure Optimized Outcomes

Paul Runyan, VP of Sales, Accumold

In today’s ever-evolving technological landscape, the demand for precision-engineered micro molded parts has skyrocketed. From medical devices to electronics, industries seek micro parts that are consistent in quality and can be produced in large volumes. However, with the growth in demand, there’s a parallel increase in micro molding companies, making the selection process for customers quite challenging. To ensure you’re partnering with a company proficient in delivering volume and repeatability, here are some essential questions you need to pose.

What is your experience in micro molding?

 Micro molding transcends the simple notion of miniaturization. It embodies the art of achieving impeccable precision and navigating the inherent complexities of creating minute components. A company seasoned in this field will inherently possess a deep-rooted understanding of the nuanced challenges and subtleties that the micro molding process presents, ensuring they produce components that meet the highest standards of quality and functionality.  Core assets to look for with any micro molder are an integrated tooling department (do they manufacture their own tools?); experience with the micro molding press of their choice (do they have the right equipment and experience level to operate the technology?); and thirdly the quality equipment and know how to prove the micro component is in specification (can they prove capability in production and hold the micro tolerances on the print?)  These are the three key aspects of traditional micro molding so any lack of confidence in these areas may cause problems when you reach the commercialization period of a project.

What materials do you specialize in, and what are their shrinkage rates?

 Material shrinkage during molding varies depending on the specific material used. Grasping these differential shrinkage rates is fundamental in the manufacturing process, as it directly impacts the dimensional precision of the final product. The divergence in shrinkage rates poses a significant challenge for manufacturers, especially in the realm of micro molding where precision is paramount. Accurately predicting and understanding these rates is not just a matter of technical knowledge; it’s a prerequisite for achieving the desired dimensions and tolerances in the final product. A slight deviation, even in the micrometers range, can render a part useless or incompatible for its intended application. Therefore, a deep comprehension of material-specific shrinkage rates is a cornerstone of ensuring that the final micro-molded product is dimensionally accurate, fit for purpose, and meets the rigorous standards of quality and precision.

An innate understanding and experience of working with as big a library of thermoplastic resins as possible is vital for a micro molder to offer an optimal service. This experience means that the micro molder is able to ask you the right questions to ensure the correct material is used. For example, what environmental conditions will the part need to operate under? Does it need to withstand solder reflow temperatures or other high-heat situations? Does it touch the human body or other bio-materials? Are there lubricity or hydroscopic properties to include or exclude?

Can you provide references or case studies from previous projects?

 Assessing a company’s track record offers invaluable insights into their proficiency and reliability. Historically, the way a company has executed its projects can often serve as a trustworthy predictor of its ability to deliver in the future. By scrutinizing their past endeavors, one can ascertain the firm’s expertise and aptitude in managing comparable tasks, allowing for an informed decision-making process when selecting a potential partner or vendor for new micro molding projects.  Most micro moulding companies will publish white papers on their website and many will have examples of prior legacy parts that show the micro scale and tight tolerances on their website.  Ask your short-listed micro molder whether they can get close to fulfilling the following.

• Parts up to 1/2” (13mm) in the largest dimension.
• Small parts around 800µm (0.031”) x 300µm (0.012”) x 380µm (0.015”).
• Thin wall sections near .004” (.1mm).
• Feature aspect ratios around 6:1.
• Part volumes 0.005”³ (0.08 cm³) or less.
• Gate size as small as 0.004” (0.1mm).
• Ejector pins as small as 0.010” (0.254mm).
• Full understanding of gate and ejection location.
• Full understanding of effect material selection can have on fill and definition of features.

How do you ensure repeatability in production?

Repeatability stands as a fundamental pillar in the realm of micro molding. It’s not just about crafting intricate components but ensuring that every single piece, even in high-volume production runs, meets the same exacting standards of quality and precision. Such consistency safeguards the reliability of the products, emphasizing the importance of meticulous process control in micro molding projects.

What quality control measures do you have in place?

In the precise domain of micro molding, rigorous quality checks cannot be overemphasized. Given the minute scale and the demand for exactness, any minor oversight can lead to significant product discrepancies. Thus, it’s imperative for companies to have a robust quality assurance system in place, ensuring that every micro-molded component aligns perfectly with the set specifications and standards, guaranteeing reliability and excellence in every production run.   Micro mold quality assurance begins at the start of each project with design for manufacturability (DfM) reviews to ensure the project is off on the right foot. Then, early in the production process, it is important scrutinize production quality and the robust nature of the process and verify the plan for inspecting and measuring outcomes.  From there, its important to develop control plans that address critical features, FMEA results, and other quality requirements. Most experienced micro molders are able to use high-tech and low-tech measurements, and precision gage pins or high-resolution in-line vision systems as necessary. It is also important to use high magnification microscopic measurements to verify tool and finished part dimensions.  Proper product handling is also a necessary consideration in quality assurance. Surface contamination can be a nuisance – or a catastrophe – for delicate component features. For these types of parts, automation and clean room molding options are recommended.

How do you handle mold design and validation?

The efficacy of the mold design and its validation process is pivotal in determining the quality of the final micro-molded product. An optimized and streamlined design process not only guarantees superior outcomes but also offers the dual benefits of cost efficiency and swifter turnaround times. Companies that invest in refining these processes are better positioned to deliver high-quality products while achieving operational savings and timely deliveries.

What is your production capacity and lead time?

Ensuring a company’s capability to meet specific volume demands and adhere to set timelines is paramount in a production partnership. This not only reflects their operational efficiency but also their commitment to client satisfaction. By verifying these capabilities upfront, one can establish a foundation for a reliable and seamless collaboration, minimizing potential disruptions and guaranteeing timely product deliveries.  Most customers look for scale – can my suppliers meet my production demands and hold the required tolerances?;  capability— does my micro molder have the assets in place to be successful in micro in size, micro in tolerance, and/or micro featured parts; sustainability – will my supplier be viable long term with a strong balance sheet.

How do you manage tool maintenance and longevity?

Consistent maintenance of molds is a critical step in ensuring their prolonged usability and efficiency. By upkeeping the molds, companies can assure that the quality of the products remains consistent over time. Additionally, this diligent approach helps in preempting and minimizing sudden production disruptions. In essence, regular mold maintenance serves as a safeguard against compromised product quality and unplanned production halts, ensuring a smooth and dependable manufacturing process.

Do you offer any post-molding services like assembly or packaging?

In the intricate world of micro molding, ensuring a company’s capabilities and expertise is paramount for clients who require high-volume and repeatable production. While the molding process itself is essential, what happens after the molding can significantly influence the quality and reliability of the final product. For prospective customers of micro molding companies, it’s vital to inquire about post-molding services. Depending on the precise needs of a project, these subsequent services can be the defining factor in achieving the desired specifications and finish for micro molded parts. As such, customers should prioritize asking detailed questions about a company’s post-molding procedures and capabilities to guarantee that the end product not only meets the set standards but is also delivered consistently across large batches.

How do you address unforeseen challenges during production?

The realm of micro molding, given its intricate nature, often presents unpredictable challenges. The minute dimensions and precision required can lead to unexpected complexities during the production process. In such a nuanced field, the true measure of a micro molding company isn’t just in its ability to produce but also in its capacity to swiftly adapt and address these unforeseen challenges. As customers navigate the market, they should recognize that a company’s adaptability and proactive problem-solving approach can significantly set it apart from competitors, making it a crucial differentiator when selecting a reliable partner in micro molding.

Do you have any certifications relevant to my industry?

In industries where precision and compliance are paramount, such as healthcare, the importance of certifications cannot be overstated. These certifications serve as more than just badges of honor; they are tangible evidence that a company consistently meets and upholds industry-specific standards and practices. By obtaining and maintaining these credentials, a company signals its dedication to excellence and its commitment to delivering products or services that are safe, reliable, and of the highest quality. For stakeholders, certifications act as a reassuring benchmark, indicating that they are partnering with an entity that understands and respects the nuances and demands of their particular industry.  Companies should look for the following ISO standards when choosing a reputable micro molder.  ISO 13485, ISO 9001, and ISO 14001 certificates which should be updated with the certificate of registration effective date, expiration date, and certification number displayed on their website or available to be reviewed.

What technologies and machinery do you employ in the micro molding process?

In micro molding, the role of modern technology cannot be emphasized enough. Employing up-to-date technology not only elevates the overall quality of the molded products but also boosts efficiency, ensuring that projects are completed in a timely manner. Furthermore, the latest technological advancements play a pivotal role in guaranteeing repeatability — a critical factor when producing high-volume batches that must maintain consistent specifications. Thus, for companies or individuals seeking a partner in the micro molding industry, the adoption and application of contemporary technology or the bespoke in-house development of cutting edge technology solutions by a firm stands as a key indicator of its ability to deliver superior and consistent results.

How do you handle design changes or iterations during the project?

In the dynamic landscape of product development and manufacturing, design iterations are often an inevitable part of the journey. As such, a company’s ability to be flexible and swiftly accommodate these design changes becomes paramount. Such flexibility not only demonstrates a company’s commitment to customer satisfaction but also leads to significant savings in both time and resources. By pre-emptively addressing and integrating modifications, potential roadblocks are avoided, ensuring a smoother and more efficient production process. Therefore, when selecting a micro molding partner, it’s wise to prioritize those that showcase this adaptability, as it can greatly influence the overall success and cost-effectiveness of a project.

How do you stay updated with industry trends and technological advancements?

In today’s rapidly evolving business environment, a company’s commitment to continuous learning and adaptation becomes a hallmark of its long-term viability. Such companies don’t just rest on their past laurels; instead, they are in a relentless pursuit of knowledge, ensuring they remain at the forefront of industry trends and innovations. By fostering a culture of ongoing education and adaptability, they position themselves to offer solutions that are not only effective but also attuned to modern requirements and challenges. For clients and partners, collaborating with such forward-thinking entities often translates to better outcomes, innovative approaches, and a shared journey of growth and evolution.

SUMMARY

Finding the right micro molding company requires due diligence and a deep dive into their capabilities and methodologies. The answers to these questions will not only give you confidence in your partner but also ensure that your micro molded parts are of high quality, delivered on time, and produced repeatably. Remember, it’s not just about finding a vendor but forging a partnership for mutual success.

www.accu-mold.com

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