Micro Molding
M3 series micro molding machines offer unparalleled performance in an extremely compact, user-friendly package. The M3 platform features patented ISOKOR™ injection technology, specifically developed to address the unique challenges of molding very small, direct gated plastic parts. From low volume prototyping to fully automated mass production, the revolutionary M3 delivers superior part quality, faster speeds, and more flexibility. The micro molding cells come in 8, 16 and 32 drop models with options available for a wide range of standard and special applications.
High Volume
M3 series machines operate using extremely compact and cost effective modular inserts, each containing eight small cavities, completely doing away with the larger, more costly plate structure of traditional injection molds. M3 cavity inserts simplify the mold design, dramatically reduce the time and cost of building molds, and speed up the transition from prototype molding to full scale production - all processing parameters remain identical, no additional validation is required for regulatory approval.
Patented Process
Conventional injection molding machines cannot mold extremely small, direct gated parts efficiently or effectively because they do not address the biggest challenge in micro molding - they cannot adequately protect the plastic from degrading. Since micro parts consume only minute amounts of material, melt flows at a very slow rate towards the cavity. Too much dwell time in the channels damages the material. Molding cold runners to move more material is not the solution. The M3 series is built around a completely new rheological process called ISOKOR™ injection. By heating the polymer to injection temperature much closer to the gate, the patented technology significantly reduces the time melt is exposed to high processing temperatures and to shear heat, minimizing melt residence time and maintaining the integrity of the resin. This eliminates both the problem of material degradation in the runners and the dependance on inefficient cold runners.
Direct-Gated Parts
M3 series injection molding machines offer all the advantages of direct valve gate hot runner technology. Eliminating cold runners improves part quality, speeds up cycle times and reduces waste in the form of scrap material. This results in substantial savings especially when molding highly valuable plastics such as PEEK or bioabsorbables. With conventional cold runner micro molding, it is common for the weight of the runner to be multiple times greater than the weight of the part produced. The M3 can direct-gate parts as small as 0.001 g with a fine Ø 0.5 mm gate. It can also mold parts with sub-runners when needed (e.g. for parts under 1mg, for ease of parts handling, or to multiply the total number of cavities).
M3 series injection molding machines offer unparalleled performance in an extremely compact, user friendly package. All models of the M3 feature patented ISOKOR™ injection technology, specifically developed to address the unique challenges of molding small, direct gated plastic parts. From prototype to mass production, the revolutionary M3 family delivers superior part quality, speed, and flexibility.
Game Changer
Advantages of ISOKOR™ technology
Better part quality
The science behind the explosive ISOKOR™ injection process explains how the patented technology achieves dramatically improved part quality. By taking advantage of the elasticity of polymer melt, M3 micro molding machines compress the melt and use the stored energy in the material to instantly and completely fill the micro cavity within millisecond after the valve gate opens. This results in better cavity replication (more accurate part features) as well as superior part strength and virtually no shrinkage.
Zero cold runner waste
Direct-gated micro parts offer a number of key advantages. Most importantly, eliminating all cold runner scrap results in substantial materials savings which can result in cost savings of millions of dollars, depending on your part. Costly engineering plastics especially, like bio-absorbable, PEEK and LCP, should never be molded using a cold runner. The environmental advantages of eliminating plastic waste speak for themselves. M3 micro molding technology lowers the cost and the carbon footprint of your plastic part.
Material integrity
Plastics are organic and their polymer chains get damaged when heated. M3 injection molding machines protect the melt from breaking down from prolonged exposure to high processing temperatures in the runners and channels, a common problem for other micro molding platforms. By always keeping the melt compressed and by keeping the plastic flowing at a very low temperature until right in front of the gate close to the time of injection, the M3 can store the liquid polymer inside the flow path for an extended period without material degradation.
High speed, high volume
M3 micro molding machines are fast, featuring extremely short cycle times. Consequently, they are ideally suited for mass production and fast turn arounds. A single 32 drop M3-D32 can produce hundreds of millions of parts per year, for example. This platform is also extremely scaleable and flexible. It is possible to prototype mold using a single cavity in the same machine with the same processing parameters, that later gets increased to up to 32 cavities.
100% automation control
M3 micro molding presses feature a host of advanced sensors throughout the system which are controlled via the HMI to provide the most comprehensive processing control in the micro manufacturing industry. Downstream part handling, cavity inspection, temperature control and ultra-sensitive pressure sensors all work together to deliver better micro parts and to offer total transparency for data acquisition and quality control.
Uniform density
Material density plays a crucial role in micro-injection molding, directly impacting part integrity, dimensional stability, and mechanical properties. During injection, variations in material density can lead to warpage, shrinkage, voids, or stress in the final part. Proper control of material density, along with factors like pressure, temperature and ultra-fast injection speed, ensures molecular integrity and perfect part quality.
ISOKOR™ 3-Step Process
Thermoplastic materials are structures of entangled polymer chains, like spring coils that have space to move, to compress and decompress. The polymer chains have a certain mobility depending on temperature and pressure. When heated up, plastic material will expand its volume and shrink during the cooling process. Above the transition temperature where the material changes from solid to melt, the specific volume of the melt increases at an even higher rate. A pvT diagram illustrates the specific volume of the melt depending on pressure and temperature. The melt is at its maximum expansion/volume at processing temperature without being pressurized. As the pressure increases, the melt compresses. When pressure is removed, it decompresses. This dynamic is typical for the conventional injection molding process, where the melt changes from a state of zero to peak pressure with each cycle. In a sense, the spring-coiled molecules compress and decompress constantly and the specific volume changes accordingly, following the pressure curve of the injection molding process. This makes it impossible to meter the exact shot weight of micro-parts. However, the melt compression and expansion can be utilized by the M3 process inside the melt distribution unit (MDU). A multi-cavity valve gate hot runner with integrated check valves and plunger pistons generates a high velocity melt injection with pre-compressed melt. The melt pre-compression stores the required elastic energy within the melt for an instant expansion in order to rapidly fill the mold cavity. The screw, plunger and valve gates interact within the molding cycle repetitively in a precise sequence (1-12). The controlled plunger forward motion closes the check valve. The plunger compresses the melt to the second level (first plateau represented by the dotted blue line). The controlled plunger force reaches the first compression state or equilibrium, followed by the desired melt injection pressure plateau (red line indicating level 2).
With the material “charged” with visco-elastic melt energy, the process is ready for the next step, level 3. With the timing of the opening of the valve gate, the micro cavity of the mold fills by melt expansion in a matter of milliseconds. During the injection phase, a continuous plunger motion re-establishes the melt injection pressure inside the MDU and mold cavity. The closing motion of the valve pin shuts off/seals the gate and the melt in the cavity reaches peak pressure with a high melt density. After valve gate closing, the plunger moves back and recharges the MDU with new melt flowing from the continuously pressurized screw cushion. Meanwhile, the melt inside the cavity solidifies at pressure to form a plastic micro-part with high polymer density, precision cavity replication and low shrinkage.
White Paper
Advancements in
Micro Molding 2025
Ready to start?
Take a minute to share your project details with us and we’ll explore the best options for your micro-injection molded parts.
Micro Lab
The MHS Micro Lab has been investing for decades in cutting-edge research and development, drawing resources and expertise from all around the globe. The result is a revolutionary new manufacturing platform for the commercial production of direct-gated micro parts.
