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micro lens examples

Examples

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

Design Guidelines

We stand alone when it comes to extremely tight tolerances and small micron sized features. Our design guideline page is updated often as our technology continues to advance.

View Our Design Guide

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.

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

Market 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

Market 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

Market 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

Market 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

Market Segment: Medical Micro 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®

Market 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

Market 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

Market Segment:Medical Micro Molding

Core Group: Micro Mold® Parts

Small Mold Parts

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.

Micro Optic Molded 12 Lens Array

Description: 12 x Ø 250 µm aspheric lenses.

Material: Ultem®

Market 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)

Market 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

Market 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®

Market 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

Market Segment: Medical Micro 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

Market 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

Market Segment: Medical Micro 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

Market Segment: Micro Electronics Molding

Core Group: Small Mold Parts

Molded Hearing Aid 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

Market Segment: Medical Micro Molding

Core Group: Small Mold Parts

Lead Frame / Insert

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.

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

Market Segment: Medical Micro Molding

Core Group: Lead Frame / Insert

Lead Frame Molded 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

Market Segment: Micro Electronics Molding

Core Group: Lead Frame / Insert

Flex Circuit Overmolding

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

Market Segment: Medical Micro 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

Market 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

Market Segment: Medical Micro 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®

Market 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

Market 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

Market Segment: Medical Micro Molding

Core Group: Lead Frame / Insert

Lead Frame Molded SO8 Package

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

Market Segment: Emerging Technologies

Core Group: Lead Frame / Insert

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