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
Aluminum mold inserts & flexible master mold concepts save time and provide the tooling you need for your small ingredient production.
Thanks to the use of aluminum, we keep tooling costs very low.
With our protosys® Rapid Tooling process, we manufacture your components using an efficient injection molding process, saving you time and unnecessary costs.
The manufactured components meet the highest quality standards.
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.
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.
Quality standards that also inspire our customers. Our high-quality and near-series prototypes are produced quickly and cost-effectively.
We are happy to offer laser marking, ultrasonic welding and component assembly for further processing of your components.
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.
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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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).
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
– Temperature resistance
– Weathering resistance
– Oxygen permeability
– Excellent compression set
– Chemical and UV stability
– Easy to color
– Part size 0.25 – 100 cm² projected area
– Shot weight 0.5 – 100 g
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.
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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