Injection moulding - total control

We injection mould both small and large parts in short series. Whether you need a functional test of a prototype or produce short series of up to 100 000 pieces.

Precision in every detail

At Prototal, we offer you security and quality throughout the entire manufacturing process. Before the actual manufacture, we simulate the injection moulding process to discover any possible errors or risks in the design – an additional safety step many of our competitors cannot offer. After that, we design the tool and provide you with production samples and reports. We continue to continuously measure and control throughout the manufacturing process.

We have some 45 modern injection moulding machines with a clamping force of between 25 and 1000 tonnes. The majority of them are equipped with robot cells for automated production. No customer is too small or large, then our batch sizes usually vary from few prototypes up to 100 000 parts in production. We work with practically all thermoplastics and additives which can be injection moulded.

Should your part require additional finishing, we can also handle that for you. We can offer assembly, printing and ultrasonic welding, for example.

Tooling

By designing and manufacturing all tools by ourselves, we control the entire process from the order stage right up to delivery, and so have complete control over quality and delivery performance. Whether simple tools for vacuum forming or the more complex tools required for injection moulding or sheet metal forming, we can adapt the process to your needs. By offering both tooling and injection moulding, we can take on overall responsibility for your entire delivery.

The tools can be adapted to different types of inlets, e.g. rod, tunnel, film and hot gate. The cavities in the mould can for example be grinded, polished, blasted, etched or spark eroded to achieve the desired surface structure on the injection moulded parts.

Simplified tools in plastic

Moulds made of 3D printed polyamide for injection moulding of prototypes in TPE. Completely manual handling during injection moulding. Part finish corresponds to SLS model. Limited lifespan of approximate 100 parts.

Prototype tools

The tool design is simplified as much as possible in accordance with the number of parts to be manufactured. The tool is manufactured in aluminium which allows quick and effective production, thereby keeping investment costs as low as possible. It can then be used to injection mould parts under normal manufacturing conditions. Generally the production run is of a few hundred parts.

Low volume tool

The tool design can also be adapted for a more automated injection moulding process. The tool is manufactured in aluminium which allows quick and effective production, thereby keeping investment costs as low as possible. It can then be used to injection mould parts under normal manufacturing conditions. The lifespan of the tool is around 100 000 shots which covers the majority of parts.

How we work

Mold flow analysis

We always simulate the injection moulding processes in order to veriify the quality. By carrying out this analysis, we can early identify any possible problems or risks with the design. It allows us to make minor adjustments and then carry out further analyses. As a result, we can reduce the number of changes and offer a more cost effective product.

Tool design

Our own toolmakers design the tools. The designed is adapted according to the tool type in order to achieve the most cost effective solution.

Milling

All of the tools we produce are milled by our very own team in our CNC toolshop. Automatic processing and picking robots which feed the milling machines make the manufacturing process even more effective.

Assembly

All of the tools are assembled by our very own team in our toolshop. It is also here we make the blasted, grinded or polished surfaces which give the final product its surface finish. Before the injection moulding process, we pressurize the tool to make sure everything is perfect.

Injection moulding

The tool is test injected to make initial samples. The injection parameters of the sample are then checked carefully to make sure they comply with the customer’s specifications. We can also provide documentation (e.g. measurement records and PPAP) upon agreement with the customer.