These molded rotors have 18 tiny teeth around the rotor's 0.092" diameter.

The fiber optic rosa shown here has an aspheric prescription lens molded right into the plastic, eliminating the need for a separate lens.

This bobbin molded in a multi-cavity mold on continuous strip. The cavity-to-cavity variation averages between .0002" and .0003".

2-Shot Micro Molding

The figure shows an example of 2-shot micro-molding. This is a process by which two different plastic materials are shot in sync so that it requires only one single operation. Customers often look to this type of process in micro-molding to remove intense labor, create a more robust part configuration or as a cost-savings measure. Other applications such as cosmetics or touch-and-feel applications are also capable at these part sizes. 

Insert Micro Molding

Insert micro-molding molds a wide variety of materials such as metal and glass in, and around plastic parts. This image shows an example of advanced insert molding capabilities. These parts, similar to 2-shot molding, not only reduce handling and assembly, they can solve critical issues in manufacturing.

The image shows a fragile insert molded into a plastic frame. This part required the mold to be built in such a precise fashion so that the glass filter was not damaged during the molding the process, all while keeping the tight tolerances of both the filter and the frame.
 

Design for Manufacturability

Accumold is a micro-molder that produces ultra-small, tight-toleranced, geometrically complex parts consistently and efficiently every time. But, we never lose sight of the fact that these parts must bring value to your finished piece. In order to accomplish this, our engineering team works closely with your design engineers at the start of every project. Discussions about multiple aspects of design, function, features, materials, tooling, production and output take place. Taking this time up front has proven to be a great way to save time and resources through the entire life of your project.

Remember, being able to manufacture these parts consistently and repeatably in both prototype volumes and high production volumes (millions+ parts per year) at affordable prices is Accumold’s strength. 

Micro Overmolding

Overmolding often refers to any process that takes one part made of plastic, metal or other material and molds "over" it in some fashion to bind two parts in one. Whether it is insert molding, lead frame encapsulation or even 2-shot process Accumold takes a micro approach.

The image to the left shows a very sophisticated overmolding process where delicate flex-circuit leads are inserted, held and shut-off around the mold to form a very tight seal. This part required careful planning and design so to not damage the flex-circuit and connector in the process. 

Automation - Packaging

Packaging and shipping micro-molded parts in lead frame and tape and reel for protection and high-speed handling are also Accumold specialties. MEMS and IC packaging industries have benefited from this type of packaging for a long time, however, any industry can see dramatic productivity improvements from these packaging systems.

Accumold can safely and accurately package your micro-mold parts. Protecting your micro-parts means your manufacturing lines receive complete inventories of undamaged, uncontaminated parts that can be processed without expensive manual labor.
 

24-7 Production Facility

All our tooling, molding, packaging and metrology are done under one roof in our 82,000 square foot facility located near Des Moines, IA. With 15 acres of property, our plans include expanding to 200,000 square feet. We are ISO 9001:2008 certified. Our plant, which operates 24-7 with three daily shifts, is completely climate controlled and has three 100K clean rooms and two 10K clean rooms.

Strategically located near the Des Moines Area Community College, which has one of the finest educational and apprenticeship programs for toolmakers in the United States, Accumold has access to some of the most skilled and brightest professionals in the business.
 

In-House Tooling / Mold Building

Depending on the part complexity and quantity, it can take 4 to 8 toolmakers to design, build and test an average tool. Cross-functional teams of designers and toolmakers work in concert to build tools that are capable of producing production-ready parts the first time.

Tools this complex require a special touch, from conception, through tool-making, to parts production, to storage.

No company can manufacture parts consistently and repeatably if they do not have a strong tool project management program in place. When comparing micro-molders, we encourage you to investigate this key process that is frequently overlooked.