Riegler expands technology portfolio in the field of micro injection molding

Precision tools for micro-injection molding are manufactured by Riegler GmbH & Co. KG to the exact hundredth of a millimeter.

Micro-injection molding manufacturing from the ISO Class 7 cleanroom.

The Hessian system supplier and plastic processing company Riegler GmbH & Co. KG has further expanded its technology platform in the field of micro-injection molding. Together with a customer, a customized micro-injection molding solution was developed, and a tool produced in-house was used. In accordance with all required cleanroom standards, Riegler GmbH & Co. KG took over the optimization and further development of an existing product in the micro-injection molding sector. Through investment and technological expansion into a fully electric micro-injection molding machine, the plastics specialist creates the perfect conditions for the production of tiny customer-specific components in an ISO Class 7 cleanroom.

Here is a current example of a customer solution in the field of micro-injection molding

Riegler was commissioned to further develop an existing product line with a total of ten different sizes, weighing from 0.2 grams to 0.26 grams. The product was previously manufactured using a tool with a cold runner system. As a result, the sprue had to be punched from the plastic component. The edges created during punching are extremely disadvantageous in the final application. By connecting with a hot runner and needle shut-off system, the punching process is eliminated, enabling economical production of the component.

Due to the sensitivity of the plastic to prolonged dwell times, the challenge was to develop a tool and machine concept that meets the requirements of the plastic as well as the product design and connection at the smallest shot weights.

It was also necessary to ensure maximum flexibility in series production when switching between different size variants.

Coordinated innovative machine and tool concept

Riegler GmbH & Co. KG invested in a fully electric micro-injection molding machine with a micro-injection module and pre-plastification for optimal process control at low shot weights. The focus in designing the manufacturing concept and processing the material type is on maintaining dwell time to avoid material degradation.

Another highlight is the injection mold developed by the company's own design department and built in-house, featuring an innovative mold change system. Here, the rotating insert is positioned on the ejector and nozzle side for each product variant. This way, the mold remains on the micro-injection molding machine during version changes, allowing immediate start of production of the new version. This eliminates costly retooling steps and increases manufacturing flexibility. Thanks to Riegler's expertise in hot runner applications and their innovative tooling concepts, the design of the item with the described requirements was implemented in a rotary changeover unit. By eliminating the sprue and post-processing steps, the manufacturing process was optimized, and part costs were reduced.

In close collaboration with the technical departments, various tool and injection molding machine concepts were examined and evaluated. Through years of experience in design, tooling, and application technology, a cost-effective and process-safe concept was developed. As a specialist in hot runner tools, customer requirements could be fully implemented without exceeding the critical dwell time of the material. "The short internal workflows enabled us to design the innovative tool in the shortest possible time, manufacture it in our own tool shop, and quickly implement the planned optimization cycles after the first sampling. Coupled with the new machine technology, this exciting project delights our customer and the Riegler team," says Dr. Thomas Taufertshöfer, project manager at Riegler GmbH & Co. KG.

Prepared for future orders in the field of micro-injection molding

"The requirements for tiny and micro components are high. Choosing the right manufacturing concept is crucial to reliably and process-safely deliver high-quality parts to the customer. With this technological expansion at Riegler, we can now also offer solutions from the ISO Class 7 cleanroom for small and micro components, including special and high-performance polymers. Customized packaging and labeling complete our range of services as a system supplier," says Thorsten Kellner, Head of Development & Project Management.