July 12, 2021

Micro injection molding, the precision crafting of tiny plastic components, is driving innovation in medical devices and electronics. At Westfall Technik, our proprietary M3 machine and ISOKOR process are revolutionizing sustainable micromolding. Acquired in December 2018 through our purchase of Ontario-based Mold Hot Runner Solutions Inc. (MHS), the M3 sets a new standard for efficiency, quality, and environmental responsibility in micro injection molding.

The ISOKOR Micro Molding Method

The ISOKOR process, developed by MHS Hot Runners, eliminates cold runners with direct gating, achieving zero-waste production—a cornerstone of Green Innovation. This hot runner technology reduces material waste by up to 90%, cuts cycle times by 50–75%, and boosts efficiency for costly polymers like polyetheretherketone (PEEK), polyoxymethylene (POM), and polylactic acid (PLA) bioresins, increasingly replacing metals in medical applications. Traditional cold-runner methods waste up to 90% of these materials, inflating costs and environmental impact. ISOKOR delivers cost savings and sustainability by minimizing waste and energy consumption.

The M3 machine, built for prototyping and high-volume production, features magnetic clamps with 10-micron resolution for mold safety, detecting even a hair on the parting line. Its 2.5-second free-fall cycle time and integrated robotic part separation maximize throughput. Designed for clean rooms, the all-electric M3 supports Industry 4.0 with secure OPC machine protocol connectivity. The M3-D08 model, with eight direct valve gates, can produce up to 100 million micro parts annually without waste, leading the way in medical device molding.

Micro Molding for Medical Devices

The medical device market is growing rapidly, driven by demand for minimally invasive solutions in drug delivery, orthopedics, and wound closure. Micro parts, often weighing 0.001–0.4 grams with tolerances of ±0.001”, require precision expertise. Westfall’s capabilities—polymer characterization, CT scanning, and automation—ensure success for medical OEMs.

ISOKOR’s direct-gating fills cavities in milliseconds, improving shot consistency, cavity replication, and eliminating defects like short shots or voids. By removing cold runners, it reduces cycle times by 4–10 seconds per cycle, saving energy and enhancing sustainable micromolding.

Leading the Micro Molding Revolution

Westfall Technik is the industry leader in micro injection molding, thanks to the M3 and ISOKOR. 

Join us in shaping the future of micromolding with big impact.

References

MarketsandMarkets. (2021). Medical Device Contract Manufacturing Market by Device Type, Services, Class of Device, and Region – Global Forecast to 2026. 

Plastics Technology. (2016). Hot Runners: A View from the Bottom Up.