INJECTION MOLDING / INJECTION MOLDING
High-performance manufacturing at the highest standard
The future-oriented production with all-electric injection molding machines and 6-axis robots is supported by a host computer system. This enables the qualified employees to plan production in real time and, together with the ERP system, ensures complete batch traceability right down to the raw material.
Quality is the common thread that runs through all departments and interfaces. Quality management works on a modular basis so that the requirements can be met seamlessly right through to medical products. Quality assurance checks the In-Process Control (IPC) characteristics agreed with the customer.
SERVICES PROFILE
- 15 injection molding machines
- Single- and two-component technology
- Clamping force from 50t to 420t
- Part weight from 0.01 g to 1 kg
- Fully automated with 3-axis and 6-axis robots
- Digitized by Leitrechnersystem:
– IST parameter recording
– Batch tracking
– Planning and monitoring - Production in ISO 7 and ISO 8 clean rooms in accordance with EN ISO 14644
- Qualified injection molding machines and validated processes
- Processing of high-performance plastics
- Processing environmentally friendly "plastics"
- Tool storage in separate fire compartment
Our injection molding services
Mythentec covers the entire range of injection molding services, from the initial product idea to the production-ready solution. Customers benefit from an integrated approach that includes development, tool design, injection molding and further processing. This results in stable processes that enable efficient and reproducible production.
Injection molding (1K/2K)
Injection molding with one- and two-component technology is at the core of the range. With a machine park of 15 all-electric injection moulding machines, components with clamping forces of between 50 and 420 tons can be produced. The spectrum of parts ranges from very small components in the milligram range to components weighing up to one kilogram.
Automation plays a central role: three- and six-axis robots perform precise handling tasks and enable stable series processes. In this way, even complex multi-component parts can be reproducibly manufactured, for example for medical instruments or technical assemblies with integrated seals.
Further processing & assembly
In addition to the actual injection molding, we offer extensive options for further processing. These include, among others:
Assembly processes - manual, semi-automated or fully automated
Ultrasonic welding - for the secure joining of plastic components
Laser marking - for traceability or permanent product information
Conditioning and packaging - up to the ready-to-sell unit on request
These steps make it possible not only to manufacture plastic parts, but also to provide them as fully assembled and tested assemblies.
Quality & certifications
Quality assurance is a central component of injection molding production at Mythentec. All processes are based on clearly defined standards that enable consistently high production quality. This is particularly important in regulated industries such as medical technology or aerospace, where traceability and process stability are mandatory.
ISO 9001 & ISO 13485
Mythentec AG is certified according to ISO 9001 and ISO 13485.
ISO 9001 is the globally established standard for quality management systems and ensures that processes are systematically monitored, documented and continuously improved.
ISO 13485 applies specifically to medical devices and their suppliers. It demands extended requirements for process safety, documentation and risk management. This lays the foundations for reliably manufacturing components for applications with high regulatory requirements.
For customers, this means a high degree of security, as projects are implemented in an environment that consistently complies with international standards and guarantees transparent traceability.
Validated processes (IQ/OQ/PQ)
Process validation is another component of quality assurance. It is always carried out when the end result cannot be fully controlled by testing - for example, in the case of complex geometries or applications with safety-critical functions.
Installation Qualification (IQ) checks whether machines and systems are installed correctly.
Operational Qualification (OQ) ensures that the processes function within the intended parameter range.
Performance Qualification (PQ) checks whether production delivers reliable and reproducible results under real conditions.
These validation steps lay the foundations for stable series processes that also meet the agreed specifications in the long term.
Production under clean room conditions (ISO 7/8)
For many applications, production in controlled environments is crucial. We offer the option of manufacturing plastic parts under increased cleanliness conditions that meet the requirements of classes ISO 7 and ISO 8 in accordance with EN ISO 14644.
In these zones, the particle concentrations in the air are strictly controlled by filter and ventilation systems. This means that even sensitive products (e.g. components for disposable medical items, diagnostic systems or sensitive electronics) can be manufactured under conditions that reliably minimize contamination.
Compliance with these standards is regularly monitored and documented. The advantage for customers is that components are not only manufactured with technical precision, but also produced in an environment that fully meets the requirements for cleanliness and hygiene.
Digitalization & traceability
A key feature of production at Mythentec is the comprehensive digitalization of production processes. All injection molding machines are connected to a control system that records and monitors process parameters in real time. This allows deviations to be detected immediately and corrections to be implemented quickly - an advantage for the stability of series production.
Digital networking also enables precise planning and capacity utilization control. Production progress can be viewed transparently at any time, which supports reliable scheduling and short response times.
Another focus is on batch traceability: with the help of an ERP system, manufactured parts can be fully traced back to the raw material used. This transparency is not only mandatory in medical technology, but also offers additional security and traceability throughout the entire product life cycle in other industries.
Materials & processing of plastics
Choosing the right plastic is a decisive factor for the functionality and cost-effectiveness of an injection molded part. We process a wide range of thermoplastics, including high-performance plastics that are suitable for particularly demanding applications. Examples include materials with high temperature resistance, chemical resistance or special mechanical properties.
Mythentec supports its customers right from the development phase with material-specific design. The aim is to design components in such a way that they meet the requirements and can be produced efficiently at the same time. Factors such as wall thickness, flow behavior and shrinkage play a role here, as they have a significant influence on the manufacturing process and product quality.
One key aspect is the processing of plastics from a DfM (Design for Manufacturing) perspective. By closely coordinating design and production, cycle times can be reduced, rejects avoided and costs cut. Customers thus benefit from components that are both technically reliable and economical.
Injection molding costs: transparent calculation
Injection molding costs are the result of a combination of several factors, which vary in importance depending on the project. In addition to the one-off investment in the mold, the cycle time, material usage and production environment have a particular impact on the unit costs. Mythentec attaches great importance to transparency: customers receive a comprehensible calculation that takes all relevant influencing factors into account.
Cost factors at a glance:
Mold costs - depending on complexity, number of cavities, tool life and hot runner system used
Cycle time and cooling time - significantly influenced by the wall thickness of the component; shorter times reduce unit costs
Cavitation - multi-cavity molds reduce unit costs, but increase initial mold costs
Material costs - determined by the price of the raw material, surcharges for high-performance plastics and quantities required
Production environment - clean room production or additional testing processes lead to higher but understandable additional costs
A number of details are required for a reliable cost calculation. This includes drawings or CAD data, desired quantities, material requirements and information on surfaces, tolerances and any post-processing steps.
Cooperation & request
The collaboration with Mythentec is geared towards making projects efficient and transparent right from the start. The company provides support in the early stages of development and industrialization in order to optimally prepare components for series production. Aspects such as material selection, tool concept and manufacturability are examined.
During series production, customers benefit from clearly defined processes, digital traceability and qualified quality management. Regular coordination and transparent communication ensure that technical requirements, deadlines and costs remain in harmony at all times.
A clearly structured process is available for inquiries: Based on drawings or CAD data, we prepare an initial assessment and check the feasibility. This is followed by a detailed offer that includes costs, schedule and technical framework conditions. This provides customers with a reliable basis for their decisions right from the start.
