Micro Molding
Precision at the Micron Level
Freudenberg Medical offers advanced micro molding capabilities for the most demanding medical and diagnostic applications. Our global sites in Beverly, Massachusetts, Carpinteria, California, Baldwin Park, California, and Kaiserslautern, Germany specialize in high-precision silicone and thermoplastic micro molding for components that are almost invisible to the naked eye, but critical to patient outcomes.
From ophthalmic devices like punctum plugs to intricate micro connectors, seals, and implantables, we deliver consistent, scalable solutions engineered for extreme precision. Because in medical technology, every micron matters.
Expertise in Silicone and Thermoplastic Molding
Freudenberg Medical provides a complete solution for micro molding using both liquid silicone rubber (LSR) and high-performance thermoplastics, including ultra-small part production and complex geometries.
Our systems include in-process vision inspection, cavity-pressure monitoring, and automated part handling, ensuring tight tolerances, exceptional reproducibility, and full traceability.
Key Capabilities:
- Silicone parts as small as 0.004 g
- Thermoplastic micro parts with shot weights from 0.05 g to 4 g
- Advanced micro injection (< 0.1 g) at our Baldwin Park, CA facility
- Tubing with inner diameters as small as 0.007 in / 0.1778 mm
- Multi-shot and bi-material micro components
- Custom tooling and fully automated production cells
- ISO Class 8 certified cleanrooms with robotic handling
Micro Molding Applications
Freudenberg Medical partners with leading OEMs in diagnostic, therapeutic, and surgical fields to develop micro molded components for ophthalmics, micro-catheters, IVD components, drug delivery systems, microneedle arrays, ENT and neurostimulation implants.
These ultra-miniature devices often incorporate features such as thin walls, micro cavities, and complex parting lines, all achievable with our team’s engineering and automation expertise.
Design for Manufacturability
At micro scale, every element of the process from material flow to mold tolerance, must be optimized. Freudenberg Medical brings decades of experience in scientific injection molding, toolmaking, and materials science to support:
- Early-stage DFM input to ensure performance and scalability
- Simulation and virtual modeling to eliminate costly trial-and-error
- High-cavitation tools with rapid cycle times
- Low-waste, repeatable processes optimized for high-volume production
Whether you require millions of parts per year or custom development for a niche therapy, we offer engineering collaboration from prototype through validation and scale-up.
Material Expertise
Freudenberg Medical offers deep knowledge of high-performance medical-grade materials tailored to micro molding
- Liquid Silicone Rubber (LSR)
- Thermoplastic Elastomers (TPEs)
- High-temperature thermoplastics (PEEK, PSU, PPSU)
- Biocompatible and implantable grades
- Drug-compatible and chemically resistant polymers
Our team helps customers select the right material based on factors such as:
- Bonding requirements and overmold compatibility
- Drug migration prevention Sterilization resistance (gamma, autoclave, EtO)
- Optical or electronic integration
Miniaturization for better Patient Outcomes
Micro molding is not just about reducing size. It is about increasing function, reducing waste, and enabling new therapies.
Advances in the miniaturization of medical devices can be a challenge:
The individual components have to be smaller and smaller to combine more functions into a single product. For example, diagnosis and treatment should take place in a single procedure. This offers many advantages: Patients are treated less frequently and for shorter periods, and they recover more quickly which reduces the strain on patients.
