Component Realization (Thermoplastic, Silicone, Micro)

Source: SMC Ltd.

Since our inception, complex thermoplastic injection molding has been a core competency at SMC. We specialize in programs that rely upon complex geometry and challenging quality requirements. Using “scientific molding” practices we assure premium components with each press cycle. With our vast array of molding options, we are confident we can align a process that best fits your medical device.

With press sizes ranging from micro to 750 ton, certified class 7 and 8 clean rooms, a wide range of molding options, and medical quality systems in place, SMC provides the highest level of quality molded components at competitive prices.

Thermoplastic Injection Molding capabilities include:

  • Insert molding
  • Silicone injection molding
  • Micro molding
  • Two-shot
  • Gas assist
  • Full range of secondary operations such as:
    • Drilling
    • Heat staking
    • Laser etching
    • Pad printing
    • Sonic welding
  • Automated systems for sub and full assembly of components


At SMC Ltd., we have proven that complex silicone parts can be produced repeatedly in nearly half the lead-time as traditional silicone molding options. With capabilities that range from up-front product development through the introduction of finished devices, we can bring your silicone program to market in the shortest time with the most predictable outcome.

SMC’s Silicone capabilities include:

  • In-house tool-making capabilities with reduced lead times
  • Automated closed-loop systems for limiting contamination
  • State-of-the-art machines with applied robotic and automation equipment
  • Precise color injection systems allowing custom colors and shades
  • Ultra precision through unique in-house mold making processes
  • Optimized cycle times
  • Design for manufacture input and options
  • Shortened mold development through in-house precision tool making
  • Wide variety of silicone materials
  • Overmolding of thermoplastics and metals with silicone
  • In-line curing systems
  • Part sizes ranging from 0.06 - 145 grams
  • Use of wide variety of self-bonding materials

The Silicone Advantage

Silicone material when combined with the process of LIM (liquid injection molding), is well suited to the unique needs of the medical device industry. Silicone materials are biocompatible, inert and stable, flexible, have a low compression set with a wide range of durometers, and offer superior heat resistance. High quality components with complex shapes can be repeated at high quantities in a cost effective manner.

Complex Contoured Geometries

Programs that require complex contoured geometries are ideal for SMC’s silicone molding process. With our in-house mold manufacturing process we can provide parts with minimal or no flash. Part sizes range from 0.06 – 145 grams.

Designing for Silicone

Designing medical device components for the silicone process requires design considerations up-front due to silicone’s unique properties. During early stages of the design process, partnering with SMC’s engineers can help identify items such as form, fit, function, parting lines, and gate placement that should be considered to achieve the best results during manufacturing. SMC’s experience with silicone applications helps to minimize problems, reduce cycle times, and lowers cost by considering the challenges of designing for silicone.

R&D Silicone Specialists

Our passion for innovation helps provide our customers the competitive advantage they need in the marketplace. SMC’s main goal is to offer speed-to-market solutions to our customers. One area of focus is silicone and thermoplastic prototyping. SMC’s R&D group can provide silicone prototype parts fast. Customers who utilize SMC’s prototype process have reduced new product development (NPD) timelines and provided valuable “lessons learned” before cutting production tooling.

SMC’s R&D group continues to investigate the latest cutting-edge technologies and silicone materials that may give our customers an edge in their market space.

Micro and Miniature Molding

At SMC Ltd., we understand that precision matters when it comes to micro molded medical parts. From 0.003 cubic inches (0.045 grams) and smaller, we can manufacture even the smallest parts while still holding precise tolerances. Our in-house tooling department is uniquely equipped to provide micro-prototyping and custom molds purposefully designed for manufacturing. When combined with our proprietary micro molding process we are able to produce robust micro parts featuring complex geometries, fast lead times, and high repeatability. When details are critical, choosing a supplier that understands precision can make the difference.

Whether your program requires a Class 7 or 8 clean room, high or low volume, SMC’s unique manufacturing approach reduces risks associated with the medical market. With expertise in validation protocols and processes we can assure conformance to your specific program requirements. Our efficient material process and adaptive tooling techniques deliver exceptional yields of 10,000 parts or 10,000 shots per pound minimum, including the runner.

We have experience in a wide variety of engineering grade materials such as:

  • PEEK™
  • Ultem®
  • Bioresorbable
  • Other engineered resins

The SMC Micro Molding advantage:

  • Medical quality systems
  • High and low volume manufacturing
  • Material yield advantage – 10,000 parts/shots per pound, including the runner
  • Initial design support for micro and miniature molding
  • Integration of micro parts into full assemblies

For tips on designing silicone medical components, as well as tips on medical micro molding, download the respective datasheets.

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