Injection molding small series

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).

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.

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.

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.

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.

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.

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.

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.

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.

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.

Our vertical injection molding machine is capable of producing high quality plastic parts at high speed and overmolding metal parts, for example. Due to the direct vertical clamping system, no separate clamping unit is required. With a clamping force of 50 tons, it can produce parts with a shot weight of up to 80 grams. Our vertical molding machine is suitable for use in a wide range of industries and applications, including automotive, electronics, medical and consumer goods.