Cons: Can be limited in feature or size capabilities; requires tooling; changes often require re-tooling.

Conclusion: This process can be a good alternative to standard hard tooling but not all rapid injection molders are set up to handle small parts.

Standard Micro-Mold hard tooling produces the exact same part as a full-production mold but speeds the process up while lowering its cost.

Capabilities: 2-micron tolerances; extremely high repeatability.

Pros: High resolution; capable of high volumes; wide range of production material; produces actual production parts; capable of insert molding; gives designers good manufacturing process insight.

Cons: Slower process; can be more expensive; tooling required; changes often require re-tooling.

Conclusion: This is the best method to produce a part to spec. However, it’s not really a rapid process.

When all is said and done, each part to be micromolded should be evaluated individually to determine the best prototyping process. Every method has its place.

Editor’s Note:
This article first appeared in the April 8, 2010 issue of Machine Design, a sister publication of Medical Design.