Accumold micro molding specializes in producing extraordinarily small plastic parts that require extreme precision. And we’ve been doing it since 1985. The micro molded parts we manufacture are commonly measured in microns. We also produce small-size parts with micro features, mold in and around existing components, and create components using intricate lead frames or inserts. We devote these specialized capabilities to every order—delivering our services with important extras:

  • Consistent, repeatable production quality
  • Scalable volumes, from prototypes to millions—or billions—of parts
  • Efficiencies that lead to affordable pricing
  • Decades of experience and expertise
  • Unparalleled industry longevity

Micro Electronics Molding

Perhaps like no other, the field of microelectronics exemplifies the drive towards miniaturization, the obvious reduction in size of everyday household appliances and cell phones showing the extent to which products containing electronic components have been reduced in size. The opportunities that exist for OEMs to ride the wave of the “next big thing” in microelectronics are huge, and in order to fully realize this potential, it is important to engage a micro manufacturing partner that can not only assist in the design of smaller electronic components, but which is also aware of the particular contingencies and issues that apply when manufacturing such components. Opportunities exist to make smaller and lighter parts, to add micro features to existing parts, or even to add new micro features to micro parts. Accumold has over 30 years experience working with OEMs as they mold complex micro-sized electronic components, and has the expertise to work at early stage design development all the way through to volume manufacture in order to exploit commercial opportunities.

 

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Micro Mold Rotor Gear

  • Description:

    Incredibly precise micro molding produces this part, with 18 teeth around the .092″ (2.3 mm) diameter and a concentricity call out of .0005″ (13 µm).

  • Material: PPA
  • Material Segment: Automotive Electronics
  • Core Group: Micro Mold® Parts

Micro Mold Shell

  • Description:

    This part is a housing for a tantalum capacitor. Its dimensions are .036″ (.91 mm) x .038″ (.97 mm) x .073″ (1.85 mm), with a .0085″ (.215 mm) hole diameter and wall thickness of .004″ (101 µm).

  • Material: LCP (Liquid Crystal Polymer)
  • Material Segment: Micro Electronics Molding
  • Core Group: Micro Mold® Parts

Small Mold Housing

  • Description:

    This part is produced in a multi-cavity tool with very little flash. Features on the inside of this part have tolerances of +/- .0005″ (13 µm).

  • Material: PBT
  • Material Segment: Micro Electronics Molding
  • Core Group: Small Mold Parts

Lead Frame Bobbin

  • Description:

    This part is molded in a multi cavity mold on continuous strip. The cavity-to-cavity variation averages between .0002″ (5 µm) and .0003″ (8 µm). After molding, the part gets singulated and formed into a standard gull wing form.

  • Material: LCP (Liquid Crystam Polymer)
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert

Flex Circuit Over-Molding

  • Description:

    This part required delicate handling of the flex circuit during processing. Careful shut-offs on the mold were required to not damage the circuit.

  • Material: Soft-touch TPE
  • Material Segment: Medical Molding
  • Core Group: Lead Frame / Insert

Lead Frame Molded Rotor

  • Description:

    The challenge in creating this part was shutting off around the lead frame without interfering with the function of the part.

  • Material: LCP (Liquid Crystal Polymer)
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert

Reel-to-Reel Micro Molding

  • Description:

    This part is first overmolded on a lead strip, then singulated and post-mold-formed into its final position.

  • Material: Nylon
  • Material Segment: Medical Molding
  • Core Group: Lead Frame / Insert

Open Cavity Package - 100 Lead Quad Pack

  • Description:

    This open air package was designed with a very tight pitch between each lead and a cavity of about .55″ (14mm) square. Shut-offs on this mold are very delicate.

  • Material: LCP (Liquid Crystal Polymer)
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert
Click here to see General Design Guidelines

Micro Mold® Parts

Micro Molding – The science of small parts

Micro molding is the essence of what we do at Accumold. We started our company on this exacting manufacturing process and it remains at the heart of our operation today. Parts made with our Micro MoId® process range in size from just microns to a half inch. These components often have complex geometry and very tight tolerances—with no margin for error.

 

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Micro Mold Alignment Spacer

  • Description:

    This part is made of LCP and is Accumold’s smallest commercial part to date. It measures 800µm x 380µm x 360um. 144,000 parts weigh 1 oz. Part handling more of an issue with this part than the tool build and production.

  • Material: Mineral Filled LCP
  • Material Segment: Micro Electronics Molding
  • Core Group: Micro Mold® Parts

Micro Mold Rotor Pinion

  • Description:

    This is a two-part assembly. The first part (the black ring) is a magnetic material molded in a plastic compound containing metal. The second part is a partial glass filled Polysulfone. We take the black ring and mold around and through it to create the assembly. Tolerances are very tight. This part must be individually packaged for protection.

  • Material: Polysulfone with Glass
  • Material Segment: Emerging Technologies
  • Core Group: Micro Mold® Parts

Micro Mold Gear

  • Description:

    Incredibly precise micro molding produces this part, with 18 teeth around the .092″ (2.3 mm) diameter and a concentricity call out of .0005″ (13 µm).

  • Material: PPA
  • Material Segment: Micro Electronics Molding
  • Core Group: Micro Mold® Parts

Micro Mold Star Wheel

  • Description:

    Considering it is unfilled material, this part has very tight tolerances. Very little flash is allowed on this part because the profile tips are bearing surfaces.

  • Material: ACE-Delrin 500CL
  • Material Segment: Automotive Electronics
  • Core Group: Micro Mold® Parts

Micro Mold Tip

  • Description:

    This part has a .010″ (.25 mm) hole that must be a clear and free of voids and bubbles. The thin wall section is .006″ (.15 mm), make it very challenging to fill with acrylic.

  • Material: Acrylic - clear
  • Material Segment: Medical Molding
  • Core Group: Micro Mold® Parts

Micro Optic Lens

  • Description:

    This UItem® part has a 100 µm diameter aspheric lens and a 125 µm base radius with a 3 µm tolerance that is critical to a part functionality.

    Dimensions of the part are .700 mm x 1.00 mm x 1.700 mm.

  • Material: UItem
  • Material Segment: Micro Optics
  • Core Group: Micro Mold® Parts

Micro Mold Shell

  • Description:

    This part is a housing for a tantalum capacitor. Its dimensions are .036″ (.91 mm) x .038″ (.97 mm) x .073″ (1.85 mm), with a .0085″ (.215 mm) hole diameter and wall thickness of .004″ (101 µm).

  • Material: LCP
  • Material Segment: Micro Electronics Molding
  • Core Group: Micro Mold® Parts

2-Shot Micromolding

  • Description:

    The hard, clear ABS part is combined with the soft, white TPU material to create a perfect bond. This process saved manufacturing resources and replaced the assembly and gluing process.

  • Material: TPU & ABS
  • Material Segment: Medical Molding
  • Core Group: Micro Mold® Parts
Click here to see General Design Guidelines

Medical Molding

It is undoubtedly fair to say that one of the key sectors driving innovation in the area of micro manufacturing and especially micro molding is the medical device industry. Demand for minimally invasive curative and diagnostic procedures is growing exponentially as patients and medical service delivery organizations seek to reduce operation and recovery times, and increase the accuracy of diagnosis. Because of this, over the last decade, medical product manufacturers have been designing (and seeking to manufacture) smaller and smaller components, with thinner and thinner walls, and complex and minute features. Couple this with the overarching demand from patients and healthcare providers to rationalize the costs associated with medical treatment, and medical device OEMs are constantly on the lookout for cost-effective and efficient manufacturing processes.

 

Visit our online partner:

MED Device Online

 

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2-Shot Micro Molding

  • Description:

    The hard, clear ABS part is combined with the soft, white TPU material to create a perfect bond. This process saved manufacturing resources and replaced the assembly and gluing process.

  • Material: TPU & ABS
  • Material Segment: Medical Molding
  • Core Group: Micro Mold® Parts

Battery Door

  • Description:

    We mold this part in several different colors. A stainless steel hinge pin has to snap into the .018″ (.46 mm) groove.

  • Material: Lexan
  • Material Segment: Medical Molding
  • Core Group: Small Mold Parts

  • Description:

    This part has a .010″ (.25 mm) hole that must be a clear and free of voids and bubbles. The thin wall section is .006″ (.15 mm), make it very challenging to fill with acrylic.

  • Material: Acrylic - clear
  • Material Segment: Medical Molding
  • Core Group: Micro Mold® Parts

Small Mold Plastic Transformer Support

  • Description:

    We make three conversions with this small mold. The thick and thin sections in this part can cause warp, but we hold a perpendicularity call of .002″.

  • Material: LCP
  • Material Segment: Medical Molding
  • Core Group: Small Mold Parts

Small Mold Pupil Dilator

  • Description:

    This part is used in optical laser surgery. To make it, Accumold molds two thin walls—each .006″ (.15 mm) thick—with very soft material.

  • Material: DOW TPU
  • Material Segment: Medical Molding
  • Core Group: Small Mold Parts
Click here to see General Design Guidelines

Small Mold Parts

Small Part Molding: Precision on a slightly larger scale

Small parts are slightly larger than micromolded parts: from a half inch to about 3 inches in diameter and made from a one-ounce shot of material- Even so, they require the same degree of precision and quality during production. Many have micron tolerances, and they can have micro-sized features measured in microns. Accumold can make in-house modifications to our presses from 12 ton to 35 tons, producing small parts with minimal waste and fast cycle times.

 

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12 Lens Array

  • Description:

    12 x Ø 250 µm aspheric lenses.

  • Material: Ultem
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Mold Molded Rotor Housing

  • Description:

    This part is center gated on the 1.237″ (3.14 cm) ID. There are 16 staking tabs that are .016″ (.41 mm) thick and .098″ (2.49 mm) tall that are tough to fill. The tolerances are very tight with call outs of .006″ (.15 mm) parallelisms and flatness of .007″ (.18 mm).

  • Material: PPA (example shown is Acrylic)
  • Material Segment: Automotive Electronics
  • Core Group: Small Mold Parts

Small Mold Lens Housing

  • Description:

    This material is 60% mineral filled, so it flows very slowly. We are capable of holding the ID bore dimensions within microns. The parallelism call out is .035 mm (.00137″).

  • Material: PPS
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Mold ROSA Connector

  • Description:

    This component has a aspheric, prescription lens molded into the plastic. We are capable of holding the ID bore dimension within microns. Coupling efficiency is being maintained at a very high level.

  • Material: PEI / UItem
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Mold Pupil Dilator

  • Description:

    This part is used in optical laser surgery. To make it, Accumold molds two thin walls—each .006″ (.15 mm) thick—with very soft material.

  • Material: DOW TPU
  • Material Segment: Medical Molding
  • Core Group: Small Mold Parts

Small Part ROSA Housing

  • Description:

    This small mold (the black part) has two core pulls, one that piggy backs over the other. They have to operate at separate times, and at different angles. The core pulls are located inside each other. Also, there are thick and thin wall sections in this part.

  • Material: PPS
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Mold Plastic Transformer Support

  • Description:

    We make three conversions with this small mold. The thick and thin sections in this part can cause warp, but we hold a perpendicularity call of .002″ (.05 mm).

  • Material: LCP
  • Material Segment: Medical Molding
  • Core Group: Small Mold Parts

Small Mold Housing

  • Description:

    This part is produced in a multi-cavity tool with very little flash. Features on the inside of this part have tolerances of +/- .0005″ (127µm).

  • Material: PBT
  • Material Segment: Micro Electronics Molding
  • Core Group: Small Mold Parts

Battery Door

  • Description:

    We mold this part in several different colors. A stainless steel hinge pin has to snap into the .018″ (.46 mm) groove.

  • Material: Lexan
  • Material Segment: Medical Molding
  • Core Group: Small Mold Parts
Click here to see General Design Guidelines

Lead Frame / Insert

Lead Frame I Insert Molded Parts: Specialized molding capabilities

Accumold can mold plastic on and around all different types of metals, plastics, fabrics, foils, devices, etc. Some of these processes produce complete parts, while others are ready for further processing by our customers or their agents. In many cases, high-speed handling can be added to these processes to save resources.

 

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Fabric Mesh Overmolding

  • Description:

    This tiny 2 mm (.08″) diameter part contains a delicate fabric mesh. Accumold developed a custom system to articulate the fabric thru the molding process as to not damage the mesh.

  • Material: HDPE
  • Material Segment: Medical Molding
  • Core Group: Lead Frame / Insert

Lead Frame Bobbin

  • Description:

    This part is molded in a multi cavity mold on continuous strip. The cavity-to-cavity variation averages between .0002″ (5 µm) and .0003″ (8 µm). This part gets singulated and formed into a standard gull-wing form after molding.

  • Material: LCP
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert

Flex Circuit Over-Molding

  • Description:

    This part required delicate handling of the flex circuit during processing. Careful shut-offs on the mold were require to not damage the circuit.

  • Material: Soft-Touch TPE
  • Material Segment: Medical Molding
  • Core Group: Lead Frame / Insert

Lead Frame Molded Rotor

  • Description:

    Our challenge involved shutting off around the lead frame without interfering with the function of the part.

  • Material: LCP
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert

Reel-to-Reel Micro Molding

  • Description:

    This part is over molded on a lead strip then singulated and post-mold formed to final position.

  • Material: Nylon
  • Material Segment: Medical Molding
  • Core Group: Lead Frame / Insert

Insert Mold Lamp Capsule

  • Description:

    We insert mold a plastic tip on the steel shaft in a micro-mold. Then we insert the shaft assembly into a small mold and mold the housing around it. The small mold utilizes two sides.

  • Material: PEI - Ultem
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert

Open Cavity Package - 100 Lead Quad Pack

  • Description:

    This open air package was designed with a very tight pitch between each lead. Shut-offs on this mold are very delicate. The cavity is about .55″ (14mm) square.

  • Material: LCP
  • Material Segment: Micro Electronics Molding
  • Core Group: Lead Frame / Insert

Wearable Switch Component

  • Description:

    This lead frame is over-molded with PEEK. The diameter of the part is approx. 4mm.

  • Material: PEEK
  • Material Segment: Medical Molding
  • Core Group: Lead Frame / Insert

Lead Frame SO8

  • Description:

    This part was run in a single cavity Micro-Mold® on a continuous lead frame. Dual lead frames were used and held .010″ (.25 mm) apart from each other. The first strip is a standard SO8 package, and the second strip is a heat sink. These parts appear to have passed a 1×10-8 fine leak hermetic test.

  • Material: TPI
  • Material Segment: Emerging Technologies
  • Core Group: Lead Frame / Insert
Click here to see General Design Guidelines

Micro Optics

Micro manufacturing technologies and capabilities are pushing at the boundaries of what is possible in the area of micro-optic component manufacture. The ability to be able to produce extremely flat, extremely small, and extremely light-weight optics today opens up a huge amount of potential for innovation. However, to be able to maximize the potential commercial benefits of what is a relatively high-cost and high-risk manufacturing environment, requires that OEMs work alongside suppliers that are expert in the manufacture of sometimes complex — and always extremely precise — refractive and diffractive micro-optical components.

 

[Click images for details]

Micro Optic Lens

  • Description:

    This UItem® part has a 100µm diameter aspheric lens and a 125µm base radius with a 3 tolerance that is critical to a part functionality.

    Dimensions of the part are .700mm x 1.00mm x 1.700mm.

  • Material: Ultem
  • Material Segment: Micro Optics
  • Core Group: Micro Mold® Parts

12 Lens Array

  • Description:

    12 x Ø 250 µm aspheric lenses.

  • Material: Ultem
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Part ROSA Housing

  • Description:

    This small mold (the black part) has two core pulls, one that piggy backs over the other. They have to operate at separate times, and at different angles. The core pulls are located inside each other. Also, there are thick and thin wall sections in this part.

  • Material: PPS
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Mold ROSA Connector

  • Description:

    This component has a aspheric, prescription lens molded into the plastic. We are capable of holding the ID bore dimension within microns. Coupling efficiency is being maintained at a very high level.

  • Material: PEI / Ultem
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts

Small Mold Lens Housing

  • Description:

    This material is 60% mineral filled, so it flows very slowly. We are capable of holding the ID bore dimensions within microns. The parallelism call out is .035 mm (.00137″).

  • Material: PPS
  • Material Segment: Micro Optics
  • Core Group: Small Mold Parts
Click here to see General Design Guidelines

Emerging Technologies

In this ever shrinking world new applications are emerging almost everyday. Accumold has considerable experience working with emerging technologies for industries like smart devices or wearables, which are often driven by weight, cost, and time-to-market considerations. These OEMs must engage with companies like Accumold in order to ensure the efficient and cost-effective manufacture of safety critical precision and micro components. Engaging with a qualified micro manufacturing partner early in the design cycle for new product development is vital to avoid multiple (and costly as well as time-consuming) design and tooling iterations.

 

[Click images for details]

Wearable Switch Component

  • Description:

    This lead frame switch is overmolded with PEEK. Its diameter is approximately 4mm.

  • Material: PEEK
  • Material Segment: Emerging Technologies
  • Core Group: Lead Frame / Insert

Micro Mold Rotor Pinion

  • Description:

    This is a two-part assembly. The first part (the black ring) is a magnetic material molded in a plastic compound containing metal. The second part is a partial glass filled Polysulfone. We take the black ring and mold around and through it to create the assembly. Tolerances are very tight. This part must be individually packaged for protection.

  • Material: Polysulfone with Glass
  • Material Segment: Emerging Technologies
  • Core Group: Micro Mold® Parts

Lead Frame SO8

  • Description:

    This part was run in a single cavity Micro-Mold® on a continuous lead frame. Dual lead frames were used and held .010″ (.25 mm) apart from each other. The first strip is a standard SO8 package, and the second strip is a heat sink. These parts appear to have passed a 1×10-8 fine leak hermetic test.

  • Material: TPI
  • Material Segment: Emerging Technologies
  • Core Group: Lead Frame / Insert
Click here to see General Design Guidelines

Specialized Capabilities

Additional Processes

Not every mold is straight forward. Accumold’s capabilities are limitless because we ask our customers to push us- daily, we define what “possible” will mean tomorrow.

Micro Structure Enhancements

Micro Structure Enhancements

Accumold combines small and micro-sized parts with the ability to mold micro structures on the surface of the part. These features can measure under one micro in size and are used in a wide variety of applications like diffractive optics, micro-fluidics or micro lenses.

Micro 2-Shot (2K Molding)

2-Shot Micro Molding

In micro molding, two different plastic materials are shot in sync during a single operation. Our customers use this type of micro molding process to lessen the amount of labor required, create a more robust part configuration, or increase cost savings. This process also is capable of handling other applications, such as cosmetics or touch-and-feel applications.

Accumold Glass Overmolding

Insert Micro Molding

Insert micro molding encapsulates a wide variety of materials such as metal, glass, fabrics, flex-circuits and other delicate media. These parts, similar to those created with 2-shot molding, not only reduce handling and assembly they can solve critical issues in manufacturing.

LDS / 3D-MID

Laser Direct Structuring (LDS) / 3D-MID

A complementary process to micro molding is Laser Direct Structuring or often referred to as 3D-MID. This selective plating process is a perfect fit with Accumold’s Micro Mold® technology. Inquire about partnering with Accumold for your micro molding part of this process.

Automotive Electronics

The automotive sector is second only to the medical sector in its use of micro manufacturing and micro molding technologies, and parts and components for the automotive industry are often manufactured in extremely high volumes. Miniaturisation of components allows for reduction in weight and cost, but also allows for the manufacture of increasingly complex and sophisticated vehicles which — in the modern world — must perform in an efficient, fuel conscious and non-polluting fashion. There are numerous opportunities for automotive OEMs to utilize micro manufacturing technologies and techniques to achieve their manufacturing objectives. Many of the applications of micro manufacturing in the automotive sector center around the use of intricate micro-electonics, which is one of Accumold’s core specialities. However, whether it is micro-electronic components or stand-alone micro plastic parts, the key to success is section of a micro manufacturing partner with a depth and breadth of understanding of the manufacturing and material possibilities that exist.

 

[Click images for details]

Small Mold Molded Rotor Housing

  • Description:

    This part is center gated on the 1.237″ (3.14 cm) ID. There are 16 staking tabs that are .016″ (.41 mm) thick and .098″ (2.49 mm) tall that are tough to fill. The tolerances are very tight with call outs of .006″ (.15 mm) parallelisms and flatness of .007″ (.18 mm).

  • Material: PPA (example shown is Acrylic)
  • Material Segment: Automotive Electronics
  • Core Group: Small Mold Parts

Micro Mold Star Wheel

  • Description:

    Considering it is unfilled material, this part has very tight tolerances. Very little flash is allowed on this part because the profile tips are bearing surfaces.

  • Material: ACE-Delrin 500CL
  • Material Segment: Automotive Electronics
  • Core Group: Micro Mold® Parts
Click here to see General Design Guidelines