Injection Molding
Our plastic production in numbers
- We have a total of 12 injection molding machines.
- With clamping forces from 25-300 tons and part weights from 0.1 to 800 grams.
- We have 4 molding machines in a separate cleanroom environment, all equipped with 4- and 5-axis robots for clean handling and automation of difficult handling processes.
- We offer both manual and fully automated 2K molding depending on the task.
- Our plastics technicians test and commission over 200 tools per year.
- We offer systematic run-ins to achieve optimal process settings.
- For production series with higher requirements for documentation and traceability, we offer a run-in process with a qualification package and associated documentation.
Cleanroom environment and robotic part handling
We are experiencing increasing demand for plastic parts with increased cleanliness requirements. We have set up a production environment with 4 machines separated from the others, where we can meet cleanliness requirements.
In our cleanroom environment, we mold and package items without human contact.
Here we offer injection molding in both aluminum and steel tools, combined with part handling by 4- and 5-axis robots that move parts from the tool directly into the packaging.
Robots can be programmed to automatically take samples throughout production and perform special handling processes, such as unscrewing threaded parts etc.
Materials and masterbatches
We have more than 500 materials and masterbatches in stock, from the most common PP, ABS and PC types to glass-filled and friction modified types. We stock certain Medico approved types and others are sourced through our network of suppliers.
With many years of experience in both product development and injection molding, we work with the customer’s requirements to find the optimal material for the job.
For 2K parts, for example, we can contribute with knowledge of the right combinations to achieve optimal adhesion.
A wide range of material types provide a good opportunity for molding parts in several different types of plastic, for example, for functional parts where material properties are essential.
Injection molding
With 12 molding machines in production, 4 of which are in a cleanroom environment, we are equipped for most molding tasks. Our operators and robots handle series from a few hundred to several hundred thousand. We offer run-in and qualification of both aluminum and steel tools, according to your needs.
Tooling
Insign was among the first in Denmark to use master moulds and the use of milled aluminum inserts for prototype tools. With a wide and flexible range of master moulds and use of aluminum inserts, Insign is able to efficiently and affordably produce a wide range of parts. Our typical lead times are 1-3 weeks, ensuring our customers’ need for fast and reliable solutions.
Advanced precision milling
At Insign, we utilize the latest technology in 5-axis precision milling, which allows us to use a milling radius down to 0.1 mm. This provides a high level of detail in the manufacture of tools, which is crucial in many industries where even the smallest variation can have a significant impact on the functionality and quality of a product.
Our prototype tools are of such high quality that they can be used for productions up to
Dedicated department for mould making
We have our own tool making department where the majority of the moulds are produced. During peak periods, we also have a network of partners that we use to manufacture moulds according to our own tool designs.
Customization for series production
If larger production quantities are requested, we also offer manufacturing of steel inserts or stand-alone steel tools. In connection to that, we offer qualification packages (IQ, OQ and PQ) on new steel tools.
Who uses prototyping tools?
Insign prototyping tools are used in a wide range of industries to validate concepts and designs including medical, wind energy, robotics, lighting, furniture and more..
Optimization of parts for moldings
With our experience in product development, tool making and injection moulding, we are able to advise on all project phases.
If needed, we can contribute with Design For Manufacturing (DFM), i.e:
- Optimization of part geometry for injection moulding.
- Material knowledge for optimal material selection.
- How to handle the part during and after molding, manual, automatic or robotic handling.
With Insign’s background and experience in mechanical product development, we can contribute with design reviews, proposals for optimizing the design, reducing amount of parts by integrating multiple functions in the same part, etc.
Use prototyping tools to
High-precision prototypes in the right materials and colors, in quantities from a few hundred to thousands. For a production start-up where time is an important factor or where final volume is uncertain. For continuous production with smaller batch sizes. And much more…
Product development
Product development is about creating a great product that can be produced quickly, simply and cheaply. And that’s exactly what Insign has helped Bang & Olufsen, Nilfisk-ALTO, Novo Nordisk and many other customers with since 1979.
Development tasks of all kinds
With our knowledge of mechanical design, materials and production methods, we can solve all types of development tasks, both turnkey projects, where we are responsible for all phases from design to finished product, and sub-tasks that are part of larger development processes.
In addition to developing new products, we also solve many tasks related to existing products that need to be redesigned to meet new requirements or changed production conditions.
Use us as your own department
For most customers, Insign acts as a kind of external development department. This means that customers can come to us with anything from a finished design to a vague idea. Then it’s our job to make the path to the end product as short and seamless as possible.
Insign’s typical development process
- Design and concept
- Construction, simulation and documentation
- Modeling phase (3d Print)
- DFM (Design For Manufacturing)
- Possible prototype tooling and trial production
- Evaluation and approval