Micro Molding Systems
M3 series micro molding systems 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.
Precision 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, LCP GF or PLA 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).
Speed, Agility
The revolutionary M3 series redefines injection molding for small, direct gated plastic parts by outperforming competing technologies by a wide margin. This new generation of electro-pneumatic molding cells delivers fully automated, high volume molding to all industries that demand extreme precision, quality and speed. M3 series machines also offer a high degree of flexibility for low volume and prototype molding without the limitations of larger, traditional injection molds found in conventional presses.
Reliable Automation
The M3 series features fully integrated, onboard automation. The touchless, robotic take-out and parts handling system uses vacuum to remove and dispense each plastic part individually for seamless downstream processing, as required by the specific application. Integrated vision inspection systems are available for a variety of quality control solutions. One option monitors each cavity before and after injection, twice per cycle, to verify correct part features.
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.
Revolutionary
One machine.
400,000 parts per day.
150,000,000 parts per year.
Zero cold runner scrap.
Unrivalled quality and speed.
Machine Specifications (M3-D08)
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Screw Diameter: 18.0 mm for all standard plastic granulates
Screw Ratio (L:D): 12:1
Screw Motor: 0 - 120 rpm, 25 N torque, 3PH 230 VAC
Barrel Heater (Front/Mid/Rear): 230 VAC 400 W / 230 VAC 400 W
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Plunger A Diameter: 4.0 mm or 6.0 mm
Plunger B Diameter: 4.0 mm or 6.0 mm
Plunger Stroke: 50.0 mm / 35 mm
Shot Size - 4 mm: 628 m³
Shot Size - 6 mm: 1430 mm³
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Valve Gate Nozzles: 8x Pneumatic Actuation
Gate-to-Gate Distance: 22.00 mm
Nozzle Heaters: 8× 140 W / 230 VAC
Nozzle Thermocouples: J-Type (Fe/CuNi)
Temperature Control: PID², 0 - 400ºC, 13 Zones
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Clamping Force: 40 kN, Electromagnetic
Maximum Daylight: 455 mm, tie-bar-less
Dry Cycle Time: < 1.0 seconds
Linear Motor Speed: 0 - 6000 mm/sec
Mold Position Accuracy: ± 0.010 mm
Mold safety and protection of delicate components and structures inside the micro mold is demanding. Linear motors, guide rails and transducers offer the most accurate speed profile for opening and closing motion in a tie-bar-less clamp unit. The motor torque control can detect any obstacle or irregularities in the motion. The powerful electromagnetic clamp force is only activated after a secure mold closing action is complete.
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Cavities: Non-Slide and Slide Mold 8 (4 + 4)
Stationary Side: Non-Slide 100 × 240 mm, Slide Mold 100 × 255 mm
Moving Side: Non-Slide 100 × 240 mm, Slide Mold 125 × 280 mm
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3 Phase Synchronous Linear Motors: 400 - 480 VAC
Mold-in-Motion™ Servo Drive: Linear Motor, 3PH 230/400 VAC
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Melt temperature thermocouples along the melt path, from the plastification barrel to the valve gate nozzle tip: 15 x Beckhoff Automation Temperature Control, J-Type FeCuNi Thermocouples
Piezo melt pressure sensors in the manifold melt channels: 2 x Kistler Type 4021B
Laser position sensors (valve gate opening and closing motion graph): 4 x Keyence LR-XH50
Laser position sensors for plunger motion (volumetric melt compression graph): 2 x Keyence LR-XH100
Cavity melt pressure sensors (optional): 2 x Kistler Type 9210
Chiller water flow sensor for cooling circuits (optional): IFM Electronic SM6604
Mold position and motion sensor: Heidenhain Linear Encoder AKLIC211
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Power Supply: 3PH 230/400 VAC, 60 A, 50/60 Hz
Load max. : 15 kW
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HMI: Microsoft Windows, 21” touch screen
USB: 1 x Standard Port
Network: 1 x Ethernet Interface
Signal Tower: Top-Mounted, Standard
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Air Pressure: 7 - 10 bar
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Material feeder/dryer
Parts handling
Clean room package
Ionized air
Vision inspection system
Conveyor
Thermolator
Customization
Advancements in
Micro Molding 2024
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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.
