Future Micro Design Guide
Welcome to the Future Micro Design Guide — your comprehensive resource for micro molding design excellence. This guide provides engineering teams with the knowledge needed to design precision micro molded components with tolerances measured in microns.
What is Micro Molding?
Micro molding is a specialized manufacturing process that produces extremely small, high-precision thermoplastic parts and components. Unlike traditional injection molding, micro molding operates at the micron level, where:
- Part weight is typically less than 1 gram, sometimes as light as 0.001 grams
- Tolerances can be as tight as ±2 microns
- Features may require 10x magnification or greater to be visible
- Wall thickness can be as thin as 0.004” (0.1 mm)
The Three Pillars of Micro Molding
A component qualifies for micro molding based on one or more criteria:
| Criterion | Description |
|---|---|
| Micro Size | Parts under a centimeter, weighing fractions of a gram |
| Micro Features | Larger parts with micro-scale features (e.g., microfluidic channels ~100 microns) |
| Micro Tolerances | Positional or geometric tolerances measured in micrometers |
Design for Micro Molding (DfMM)
Traditional Design for Manufacturing (DfM) principles don’t translate directly to micro scale. Design for Micro Molding (DfMM) requires engineers to rethink fundamental assumptions about:
- Gate placement and sizing
- Draft angles and parting lines
- Wall thickness transitions
- Material flow behavior
- Ejection strategies
At the micro scale, a 0.005” shift can render a feature unusable or make a part unmoldable altogether.
Guide Contents
This design guide covers:
- Design Fundamentals — Core principles and DfMM concepts
- Material Selection — Choosing the right thermoplastics for micro applications
- Part Design — Wall thickness, draft angles, features, and tolerances
- Tooling & Mold Design — Gates, runners, venting, and mold considerations
- Quality & Metrology — Measurement, validation, and process control
- Defect Troubleshooting — Common issues and solutions
Getting Started
If you’re new to micro molding, we recommend starting with the Design Fundamentals section to understand the unique challenges and considerations of this precision manufacturing process.
For specific design questions, use the navigation to jump directly to the relevant section.