As technology pushes for smaller, more efficient designs, micro molding emerges as a key solution for producing tiny components with exceptional precision. Discover how thermoset polyurethanes provide unparalleled customization and flexibility for your next project.
What You'll Learn:
- The fundamentals of micromolding
- Benefits of thermoset polyurethanes
- Ideal applications for micro molded components
What is Micro Molding?
Micro molding is a specialized manufacturing technique that introduces liquid materials into a mold cavity to produce extremely small and precise components, often the size of a dime or smaller. This innovative process can range from simple liquid transfer to complex automated systems, with the part size dictating the necessary materials and techniques. While traditional thermoplastics like silicone and polyethylene are commonly used, thermoset polyurethanes offer unparalleled customization and flexibility, making them ideal for a wide array of applications.
Understanding The Process of Micro Molding
Micro molding employs traditional molding processes - such as cast molding or injection molding, scaled down at a micro level. The process can be as straightforward as transferring liquid materials into a mold cavity or as intricate as a fully automated system. The size of the part heavily influences the selection of materials and techniques required to achieve the desired results. For instance, micro parts demand tooling with precisely machined micro features, while tooling with larger features typically produces larger parts. Common materials for micro molding often include high-volume injection molded thermoplastics, such as silicone or polyethylene. However, micro molding can also be achieved using cast elastomeric materials, like thermoset polyurethanes, for enhanced performance and flexibility.
The Benefits of Micro Molding with Polyurethanes
Micro molding with thermoset polyurethanes, in particular, enables product designers almost unlimited design freedom and low to high volumes. Unlike its thermoplastic cousin, TPU, thermoset polyurethanes offer a significant amount of customization at any stage in development. For instance, thermoset polyurethanes can be chemically engineered into a solid or foam with varying levels of customizable properties, such as abrasion resistance, hardness, and Coefficient of Friction (COF) to name a few. For this reason, micro molding with thermoset polyurethanes can be a great solution to develop custom prototypes for validation to small and large volumes. To learn more about the differences between thermosets and thermoplastics, click here.When to Consider Micro Molding with Polyurethanes
Many applications rely on small products and components where size and performance may be an issue. Micro molding, especially with thermoset polyurethanes, is typically ideal for applications including military & defense, medical devices, and packaging to name a few. Take the semiconductor industry as an example. Semiconductors endure extreme environments including corrosive chemicals, high temperatures, and extreme wear. When designing with thermoset polyurethanes, product designers can share specific physical property requirements with their manufacturer to meet demanding environmental concerns. Avoiding key details like this could possibly be a disadvantage to how our favorite electronic devices perform or cause significant damage while in use. To avoid any mishaps, micro molding with thermoset polyurethanes should be considered if customizable properties and molding flexibility are important factors in your product design.
Are you interested in exploring thermoset polyurethanes for your micro molded design? Complete our design tool, here, or download our Durethane data sheet below to see some of the superior properties we can offer through our adaptable manufacturing process.
