Our smallest precision commercial component to date, that we can show, is roughly 800µm (0.031”) x 300µm (0.012”) x 380µm (0.015”). The part is an LCP alignment spacer for a small photonics device. We can make 144,000 of them out of a single ounce of resin.
Thin-wall sections on micro molded parts are near .004″ (.1mm) and feature aspect ratios are around 8:1 (material dependent). Part volume is .005 in3 (.08 cm3) or less and gate sizes can be as small as Ø .004” (Ø.1mm) with ejector pins as small as Ø .010” (Ø .254mm).
In our own thin-wall study, we were able to produce one part with a 64:1 aspect ratio.
Obviously, material selection can greatly affect the fill and definition of features, so it’s always important to bring us into your process earlier than later. Keep in mind these are general guidelines. We have made smaller parts, but because they are a customer’s intellectual property, we can’t expand in much detail. It’s best to simply reach out to us and let us know what you’re working on so we can help.