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Small batch production of plastic injection molded parts

The protosys® rapid tooling process makes it possible to realize small series in optimum quality in the shortest possible time.  By using aluminum mold inserts and flexible master mold concepts, we can extremely reduce processing times and mold costs compared to steel molds. Tooling costs are usually only 10 to 25% of a normal steel injection mold.

We process all thermoplastics from PE to PEEK, thermoplastic elastomers and liquid silicone (LSR).

Convince yourself of the advantages of the Rapid Tooling process for the production of small series made of plastic and contact us!

Your advantages at a glance:

The advantages of our injection molding small series

Fast small batch production

Aluminum mold inserts & flexible master mold concepts save time and provide the tooling you need for your small ingredient production.

Cost effective tooling production

Thanks to the use of aluminum, we keep tooling costs very low.

Efficient manufacturing

With our protosys® Rapid Tooling process, we manufacture your components using an efficient injection molding process, saving you time and unnecessary costs.

Maximized quality

The manufactured components meet the highest quality standards.

Customized injection molding process

Whether standard injection molding, multi-component injection molding, sandwich injection molding, foaming, silicone injection molding, in-mold labeling, gas injection technology or the overmolding of metal inserts – our process is tailored to your requirements.

Individual use of materials

We process all thermoplastics. Starting with standard plastics (e.g. PE), through technical thermoplastics (e.g. PBT / PA) to high-performance plastics (e.g. PEEK) and even LSR – liquid silicone. The material application possibilities are manifold.

Prototypes close to series production

Quality standards that also inspire our customers. Our high-quality and near-series prototypes are produced quickly and cost-effectively.

Component machining +

We are happy to offer laser marking, ultrasonic welding and component assembly for further processing of your components.

Focus on adherence to delivery dates

Reliability is a top priority for us. We always meet promised deadlines and thus offer you the highest degree of planning security.

Injection molding small series - From your inquiry to order fulfillment.

Request a quote and upload data
Quotation preparation within 2 working days
Commissioning of small series production
Definition of the quality characteristics
Our Doing - Production of the small series
Satisfied customer - thank you for your trust!
Our services
Small series plastic injection molding parts

The injection molding process is usually associated with the efficient production of high volumes, but also with high mold costs. This does not have to be the case! (…)

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LSR small series

BARLOG Plastics’ protosys® services can now be worked with fully functional components made of LSR series material already in the development phase. (…)

Details
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You have questions
about our services?

Then do not hesitate to contact us. Together we will
take a look at your request and will be happy to advise you.

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Our application examples

Case Study
KEBABLEND / TC optimizes the thermal management of the battery in the Rinspeed MetroSnap
Read more

What our customers say

"We experience the cooperation as very result-oriented. The effective combination of design, simulation and prototypes/tools as well as the quality of the delivered parts makes you a valuable partner. The ability to react to dynamic boundary conditions as well as challenges that arise at short notice should be emphasized. Possibilities are always openly weighed and discussed together with the risks. It is important to mention that we particularly appreciate the speed of communication, as we always have all the information at hand. Working with you has made our own way of working a bit more professional."
Robby ZitzmannABB AG
"From the idea to the product it is a very long way with many ups and downs. Who motivated us again and again were you. Partners who have brought in competent services and high-quality parts, with whom we have always worked together towards a goal, but above all partners who have confirmed us in what we are doing - thank you for that."
Bianca Triulzi & Thomas TraubEbano Design GmbH
"Significantly shortened project time compared to conventional test tools, attractive price-performance ratio, parts at series level, high adherence to schedules and excellent communication during the entire project phase. This is excellence!"
"I would like to take this opportunity to thank you for the close and orderly cooperation during the project. The cooperation was extremely solution-oriented and characterized by above-average commitment. Many thanks for this!"
Michel SchneiderThomas Magnete GmbH
"In order to be able to constantly improve our product, we are happy to call on their expertise. Barlog stands out for always providing us with competent and fast help."

Everything you need to know.

Here you can find more information about our products.

Small batch production of plastic injection molded parts

We offer small batch production of plastic injection molded parts in the shortest possible time and optimum quality.

The protosys® Rapid Tooling process – By using aluminum mold inserts and flexible master mold concepts, we extremely reduce machining times and tooling costs compared to steel molds. Tooling costs are typically only 10 to 25% of a standard steel injection mold.

This cost advantage is achieved through fast machining in the HSC milling process, modular master molds and mold inserts, and a simplified mold design. We achieve output quantities up to over 50,000 pieces per year by selecting special aluminum grades and using renewable coatings.

We manufacture your high-quality small series from thermoplastics from PE to PEEK, thermoplastic elastomers and liquid silicone (LSR).

LSR small series

Fast, efficient and close to series production. Prototypes and small series made of LSR

 

The protosys® services of BARLOG Plastics can now be worked with fully functional components made of LSR series material already in the development phase. For this purpose, BARLOG Plastics produces an LSR prototype using injection molding from the customer’s virtual 3D CAD component via mold design, including rapid tooling. You benefit directly from near-series experience and results, and do so particularly quickly, cost-effectively and efficiently.

 

 

 

LSR processing: BARLOG Plastics know-how opens up many possibilities

 

LSR processing requires sophisticated process engineering, which BARLOG Plastics has optimized for the LSR prototype sector. Due to the low viscosity of LSR, BARLOG Plastics can process the components directly by injection molding using a mixing and metering system. Special units are used on the injection molding machine for this so-called liquid injection molding.

 

LSR: A material with high potential

 

– Ideal for short time-to-market processes

– Wide range of applications from consumer products to automotive, sanitary and medical technology

– Special electrical properties (insulating or conductive)

– Consistent mechanical properties over a wide temperature range

– Processing free of split products and reinforcement of the final material properties by on-site annealing possible

– Curing of liquid components in evacuated mold at 140 – 230° C

 

LSR: Many advantages, many possibilities

 

– Elasticity

– Temperature resistance

– Weathering resistance

– Oxygen permeability

– Excellent compression set

– Chemical and UV stability

– Biocompatibility

– Easy to color

– Part size 0.25 – 100 cm² projected area

– Shot weight 0.5 – 100 g

What is the Rapid Tooling process?

Based on your 3D component design, we manufacture aluminum mold inserts on our HSC milling machines and fit them into our flexible master mold system. In the rapid tooling process, we mostly produce injection-molded prototypes. However, it is just as suitable for the production of pilot series, as bridge tooling and for the production of small series.

What output rates can be achieved with aluminum mold inserts?

With non-reinforced standard plastics, we can easily offer small series of up to 50,000 units per year over several years. In the case of reinforced plastics, special coatings are used for the mold inserts in order to optimize the service life of the mold inserts and minimize maintenance requirements. In individual cases, however, we also use mold inserts made of steel from the outset in order to be able to guarantee your desired quantities.

Are there any restrictions on component geometry?

If your component geometry can be manufactured by injection molding, then we can also represent it in the rapid tooling process. We will be happy to advise you on design suitable for production and plastics and verify manufacturability using injection molding simulations in our CAE department.

Are changes to the component geometry possible in the current project?

Thanks to our certified quality management system according to ISO 9001:2015, change management is ensured during the ongoing project. The rapid tooling concept with mold inserts in master molds enables virtually unlimited change grinding of your component geometry, which we realize for you quickly, easily and cost-effectively.

Which plastics can be processed in the Rapid Tooling process?

If a plastic can be thermoplastically processed by injection molding, we can also use it for the production of prototypes and small series in the rapid tooling process. Regardless of whether standard plastics such as PE, PP or PS, technical thermoplastics such as PA, PBT or ABS or high-performance plastics such as PPA, PPS or PEEK. The possibilities for material selection are unlimited and even highly filled, fiber-reinforced or slip-optimized plastics are no problem – the full freedom of the injection molding process even for small quantities.

Which plastics are available for small series?

You have full material freedom and can provide us with any plastic for your project. We will also be happy to procure your desired material through our network. But the quickest way is to select one of the more than 200 materials we have in stock at all times. And if you have very special requirements, we will even develop your personal plastic with customized properties.

What injection molding processes are available?

In addition to standard injection molding on machines from 60 to 4500 kN clamping force, we also offer injection molding prototypes and small series in special processes, such as multi-component injection molding, sandwich injection molding, foaming, silicone injection molding or gas injection technology. Overmolding of metal inserts or inmold labeling are also common injection molding processes. In addition, we also offer further processing of your components, for example by laser marking, ultrasonic welding and component assembly.

What is BARLOG's unique selling point in small batch production using injection molding?

protosys® Rapid Tooling is a component of our comprehensive range of engineering services. This ranges from the initial product idea, through material selection, design suitable for plastics, FEA structural analyses, injection molding simulations, laboratory tests and CT scans, to series production. The combination of development services with the material expertise of a compounder is unique. At BARLOG Plastics, you get the complete know-how from material formulation, compounding and product development to the finished plastic part from a single source.

How does the quotation process work?

Send us your request via our offer form. There you can also transfer your 3D data securely and encrypted and we guarantee the confidentiality of your data and your request. Our experts will check your request immediately and usually provide you with your personal, free and non-binding offer within one working day after receiving complete request data.

Are there other options for secure data transmission?

If your company does not allow encrypted data transfer via the Internet, you are welcome to provide us with your 3D data via Odette or TeamBeam. Please contact us by e-mail or telephone: +49 2206 90851-100

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questions about our
products or services?

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Our team will be happy to advise you in a
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