Sometimes it is necessary for the product to be lighter than the specific weight of the raw material. In these cases there is a technology for foaming the raw material. This technology requires understanding and know-how in order to achieve the required weight without detracting from the geometry.

There are products whose closed geometries make it technologically difficult to produce them by injection molding. Such products will be designed in two or more segments that are then joined via ultrasonic welding. Designing a product for ultrasonic welding requires extensive know-how in welding processes and techniques. There are also cases where it is not cost-effective to insert small metal threads during the injection process but rather through a process of ultrasonic insertion that requires careful design and specialized production expertise.
NOTE: Improper design of the product and/or the process can cause cracks, fractures or a poor grip on the inserted metal parts.

For products with metal implants, the implants are inserted into the mold before closing the mold for injection – sometimes by hand and sometimes in an automated fashion. This technology requires know-how and experience both in building a mold that takes into account the expansion of the metal implant due to heat, as well as in designing how the plastic will grip the implant.

Multiple injection processes can be required for various reasons such as: thick walls, need for high precision, centering the product within a mold or combining different materials. In such cases the product undergoes an initial injection phase and is then transferred to a second mold for another injection. The challenges of multiple injections are: the sealing of the mold based on the plastic material already injected; the professional know-how of bonding the additional injected material with the initial material.

Sometimes it’s necessary to quickly and precisely identify an item in order to streamline the work process or in order to uniquely identify an item with a very high level of reliability.

In these situations barcode labeling is usually the best solution.

Although the barcode can be added to the product in a number of ways, laser marking is the optimal solution, with the following advantages:

• Etching on a wide variety of materials
• Maximal precision at a high resolution that ensures quick and precise readings during scanning
• High repeatability and uniformity
• Durable over time even in harsh environmental conditions
• Does not peel off