Capability Index · 8 disciplines
What we make, and to what tolerance.
Choose a discipline, then open any row for its design rules, tolerances and the materials we run.
IDCapabilitySpecToleranceMaterials
FM.001Micro injection moldingShot 0.004–2.5 g±10µmPEEK, LCP, COC, Ultem
Micro injection molding
Purpose-built micro-molding cells run sub-gram shots in high-performance thermoplastics with cavity control measured in microns. Dedicated screw-and-plunger architecture eliminates the residency issues that plague conventional presses at these volumes.
Key features
- Shot weights from 0.004 g with ±0.3% repeatability
- Two-stage screw/plunger injection unit
- Cavity pressure closed-loop control
- Servo-electric clamping, 50–150 kN
- Tool temperatures to 220 °C for high-flow resins
Typical applications
- Drug-delivery microparts
- Micro-fluidic chips and lab-on-chip
- Optical light pipes and lenses
- Hearing-aid and neurostimulator housings
Equipment
- Sodick LP20EH3
Standards
- ISO 9001:2015
Design rules
Dimensional DfM limits
Standard values run on routine schedules. Advanced values are quote-gated and may add tooling cost or lead time.
ParameterStandardAdvancedUnitsNotes
ParameterMin wall thicknessStandard0.15Advanced0.08UnitsmmNotesUnfilled resins; add 0.05 mm for 30% glass-filled.
ParameterMax wall thicknessStandard2.0Advanced3.5UnitsmmNotesAbove 2 mm: sink risk, longer cycle.
ParameterWall thickness variationStandard±25Advanced±10Units%NotesUniform walls reduce warp and sink.
ParameterMin draft angleStandard0.5Advanced0.25Units°NotesAdd 1° per 0.025 mm texture depth.
ParameterMin internal corner radiusStandard0.05Advanced0.02UnitsmmNotesSharp corners concentrate stress and flow-front turbulence.
ParameterMin feature sizeStandard0.10Advanced0.025UnitsmmNotesDriven by tool-cutting limits.
ParameterMax rib aspect ratio (H:W)Standard3:1Advanced6:1Units—NotesAdvanced requires polished draft and vacuum venting.
ParameterMin gate diameterStandard0.15Advanced0.08UnitsmmNotesPin-point and sub-gate options for vestige-free parts.
ParameterMax flow length / wallStandard150:1Advanced300:1Units—NotesResin-dependent; LCP reaches higher ratios than PEEK.
ParameterMin hole diameterStandard0.10Advanced0.05UnitsmmNotesDepth-to-diameter limit 4:1 (std), 8:1 (adv).
ParameterMin text/emboss heightStandard0.10Advanced0.05UnitsmmNotesRaised text molds easier than recessed.
Values are guidance for early-stage design. Final limits are confirmed in DfM review against your resin, cavity count, and inspection plan.
Process window
Machine and cycle limits
ParameterMinMaxUnitsNotes
ParameterShot weightMin0.004Max2.5UnitsgNotes—
ParameterClamp forceMin50Max150UnitskNNotes—
ParameterTool temperatureMin40Max220Units°CNotesOil-heated high-temp tools for PEEK/LCP.
ParameterMelt temperatureMin180Max420Units°CNotesResin-dependent.
ParameterInjection pressureMin—Max3000UnitsbarNotes—
ParameterCycle timeMin3Max45UnitssNotes—
ParameterPart envelopeMin—Max50 × 50 × 25UnitsmmNotes—
Tolerance capability
Achievable tolerances by feature class
All tolerances verified on a temperature-controlled OGP SmartScope G45. Advanced values require dedicated setups and additional inspection time.
FeatureStandardAdvancedInspection methodNotes
FeatureLinear dimension (< 5 mm)Standard±5 µmAdvanced±2 µmInspection methodOptical CMMNotes—
FeatureLinear dimension (5–25 mm)Standard±10 µmAdvanced±5 µmInspection methodTactile CMMNotes—
FeatureDiameter (< 5 mm)Standard±5 µmAdvanced±2 µmInspection methodAir gauge / opticalNotes—
FeatureFlatness (over 25 mm)Standard10 µmAdvanced5 µmInspection methodOGP SmartScope G45Notes—
FeaturePosition (true position)Standard±8 µmAdvanced±3 µmInspection methodOptical CMMNotes—
FeatureSurface roughness (Ra)Standard0.2 µmAdvanced0.05 µmInspection methodOptical profilometerNotesSPI A-1 finish achievable on optical inserts.
Material matrix
Resins routinely run
Additional grades available on request. Biocompatibility and regulatory documentation supplied with material certificates.
MaterialTypical gradesThermalShrinkageNotes
MaterialPEEKTypical gradesVictrex 450G, 150CA30ThermalTg 143 °C · Tm 343 °CShrinkage1.2%NotesImplantable-grade available. Autoclavable.
MaterialLCPTypical gradesVectra E130i, Sumikasuper E6000ThermalHDT 240 °CShrinkage0.1–0.4%NotesLowest shrink; tight-tolerance connectors.
MaterialCOCTypical gradesTopas 5013, 6013ThermalTg 135 °CShrinkage0.6%NotesOptical clarity; low autofluorescence for diagnostics.
MaterialUltem (PEI)Typical grades1010, 2300ThermalHDT 200 °CShrinkage0.7%NotesAutoclavable; gamma-stable.
MaterialPCTypical gradesMakrolon Rx2440ThermalHDT 135 °CShrinkage0.6%NotesTransparent; medical-grade.
MaterialPPSUTypical gradesRadel R-5500ThermalHDT 207 °CShrinkage0.7%NotesRepeated steam sterilization.
Lead time
Service-level windows
StageStandardExpedite
StageDfM feedbackStandard3–5 business daysExpedite48 h
StagePrototype toolingStandard3–5 weeksExpedite2 weeks
StageFirst-shot samplesStandard1 week after toolExpedite48 h after tool
StageProduction releaseStandard2–3 weeks validationExpedite1 week compressed IQ/OQ/PQ
Expedite windows subject to load. Confirm on quote.
Accepted file formats
STEP AP203/214/242IGESParasolid (x_t)Native SolidWorks (.sldprt / .sldasm)PDF drawings
Materials routinely run · PEEK, LCP, COC, Ultem
FM.002Insert moldingTool-fed insertsPer quoteMetal inserts + medical-grade polymers
Insert molding
Metal and ceramic inserts presented to the cavity through a feed mechanism designed into the mold itself — no robot, no vision, no secondary press. The tool indexes each insert into position between shots on the LP20EH3, so insert molding runs at near-MIM cycle times. Feed geometry is designed case-by-case at the DfM stage around the specific insert.
Key features
- Feed designed into the mold base — runs on the standard LP20EH3 cell
- Near-MIM cycle times; no secondary press or transfer step
- Feedability reviewed case-by-case at DfM
- Mechanical interlock primary; primer or plasma bond on request
Typical applications
- Cannula and needle hub assemblies
- Encapsulated contact pins and terminals
- Hypotube and small-tube encapsulation
- Threaded brass boss encapsulation
Equipment
- Sodick LP20EH3 with insert-feed tooling
Standards
- ISO 9001:2015
- USP Class VI compatible plastics
Materials routinely run · Metal inserts + medical-grade polymers
FM.003Thermoplastic composite compression moldingContinuous-fiber UD tape · matched diePer quoteCF/PPS, CF/PA UD tape · PAEK-family on request
Thermoplastic composite compression molding
Matched-die consolidation of continuous-fiber thermoplastic tape (CFRTP) into near-net flat, channel, and ribbed parts. Every edge is molded rather than routed from laminate plate, so there are no cut fiber ends, and the stiffness comes from section — a rib or a shallow top-hat — that routed plate cannot have. The dies are cut in the same toolroom that machines our micro-mold cavities. No freezer, no out-time, no B-stage: thermoplastic tape stores at room temperature indefinitely. Line commissioned 2026; first parts molded September 2026. First-article data is shared as it is generated.
Key features
- In-house heated-platen press, 62 kN (7 US ton), platens to 400 °C
- Consolidation window 10–20 bar for this tape class — about 310 cm² of projected area at 20 bar, so small parts run as multi-cavity family tools
- Molded edges on every feature; no routed cut-fiber ends
- Matched steel dies designed and cut in-house on the GRA100
- Room-temperature tape storage: no freezer, no out-time, no B-stage
Typical applications
- Unmanned aerial systems & defense
- Semiconductor & wafer-handling equipment
- Robotics & automation
- Aerospace secondary structure
- Energy & battery modules
Equipment
- In-house heated-platen compression press, 62 kN
- Jingdiao GRA100 (matched dies)
Standards
- ISO 9001:2015
Process window
Machine and cycle limits
ParameterMinMaxUnitsNotes
ParameterPress forceMin—Max62UnitskNNotes7 US ton. Available projected area follows from consolidation pressure: about 310 cm² at 20 bar.
ParameterPlaten temperatureMin—Max400Units°CNotesCovers PPS (300–330 °C) and polyamide tapes; PAEK-family evaluated on request.
ParameterConsolidation pressureMin10Max20UnitsbarNotesTypical window for continuous-fiber thermoplastic tape; set per material data sheet.
Accepted file formats
STEP AP203/214/242IGESParasolid (x_t)Native SolidWorks (.sldprt / .sldasm)PDF drawings
Materials routinely run · CF/PPS, CF/PA UD tape · PAEK-family on request
FM.0045-axis micro millingØ 0.1 mm tool±1µmTool steel, SS, Ti, Al, W-carbide, graphite, PEEK, Ultem, Delrin
5-axis micro milling
Simultaneous 5-axis milling on a Jingdiao GRA100 with 32,000-RPM HSK-32 spindle and 0.1 µm linear scales. Configured for hard-milling mold inserts directly in fully hardened steel.
Key features
- HSK-32 spindle to 32,000 RPM
- Trunnion A/C simultaneous 5-axis
- Linear scales on all linear axes, 0.1 µm resolution
- Hard-milling to 62 HRC
- On-machine probing for setup and in-process check
Typical applications
- Micro-mold cores and cavities
- Optical mold inserts
- Precision jigs and fixtures
Equipment
- Jingdiao GRA100 (32k RPM, 5-axis)
Standards
- ISO 9001
- Metrology traceable to NIST via OGP G45
Design rules
Dimensional DfM limits
Standard values run on routine schedules. Advanced values are quote-gated and may add tooling cost or lead time.
ParameterStandardAdvancedUnitsNotes
ParameterMin tool diameterStandard0.1Advanced0.05UnitsmmNotesCarbide std; PCD/diamond on advanced.
ParameterMin internal corner radiusStandard0.05Advanced0.025UnitsmmNotesDriven by tool radius — sharp internal corners are not feasible with milling alone.
ParameterMin feature sizeStandard0.10Advanced0.05UnitsmmNotes—
ParameterMin wall thicknessStandard0.15Advanced0.08UnitsmmNotesDeflection-limited on slender walls; fixture matters.
ParameterMin hole diameter (milled)Standard0.10Advanced0.05UnitsmmNotes—
ParameterMax hole depth ratio (D:Ø)Standard10:1Advanced20:1Units—NotesPeck-drill strategy; chip evacuation is the limiter.
ParameterMax pocket depth ratio (D:Ø tool)Standard4:1Advanced8:1Units—NotesAdvanced requires tapered tool or long-reach holder.
ParameterSurface roughness (Ra)Standard0.4Advanced0.1UnitsµmNotesFinish-pass with diamond on non-ferrous; polished steel on advanced.
ParameterMax part envelopeStandard120 × 100 × 100Advanced—UnitsmmNotesGRA100 work envelope — confirm against fixturing for 5-axis clearance.
Values are guidance for early-stage design. Final limits are confirmed in DfM review against your resin, cavity count, and inspection plan.
Process window
Machine and cycle limits
ParameterMinMaxUnitsNotes
ParameterSpindle speedMin—Max32,000UnitsRPMNotes—
ParameterPositioning accuracyMin—Max±1UnitsµmNotes—
ParameterAxis resolutionMin0.1Max—UnitsµmNotesLinear glass scales.
ParameterRapid traverseMin—Max30Unitsm/minNotes—
ParameterTrunnion rangeMin−30Max+120Units° (A-axis)NotesC-axis continuous 360°.
ParameterMax part weightMin—Max30UnitskgNotesTrunnion payload limit — confirm for specific fixture.
Tolerance capability
Achievable tolerances by feature class
All tolerances verified on a temperature-controlled OGP SmartScope G45. Advanced values require dedicated setups and additional inspection time.
FeatureStandardAdvancedInspection methodNotes
FeatureLinear dimension (< 25 mm)Standard±2 µmAdvanced±1 µmInspection methodOGP G45 videoNotes—
FeatureLinear dimension (25–100 mm)Standard±5 µmAdvanced±2 µmInspection methodOGP G45 video + TP20Notes—
FeatureDiameter (< 10 mm bore)Standard±2 µmAdvanced±1 µmInspection methodOGP G45 videoNotes—
FeatureFlatness (over 25 mm)Standard2 µmAdvanced1 µmInspection methodOGP SmartScope G45Notes—
FeaturePosition (true position)Standard±3 µmAdvanced±1.5 µmInspection methodOGP G45Notes—
FeaturePerpendicularity / parallelismStandard±2 µmAdvanced±1 µmInspection methodOGP G45 touch probeNotes—
FeatureSurface roughness (Ra)Standard0.4 µmAdvanced0.1 µmInspection methodOptical profilometryNotesMirror-finish milling on non-ferrous; secondary polish on steel.
Lead time
Service-level windows
StageStandardExpedite
StageDfM feedbackStandard3–5 business daysExpedite48 h
StageFirst articleStandard2–3 weeksExpedite1 week
StageShort-run productionStandard3–4 weeksExpedite2 weeks
Expedite windows subject to load. Confirm on quote.
Accepted file formats
STEP AP203/214/242IGESParasolid (x_t)Native SolidWorks (.sldprt / .sldasm)PDF drawings
Materials routinely run · Tool steel, SS, Ti, Al, W-carbide, graphite, PEEK, Ultem, Delrin
FM.005DfM consultationCAD review——
DfM consultation
Design-for-Manufacturability review by senior toolmakers and process engineers. We flag draft, wall thickness, gate placement, and tolerance stack issues before tool cutting begins — calibrated to what the LP20EH3 and GRA100 will actually run.
Key features
- Full CAD markup with change recommendations
- Material selection guidance
- Tooling cost and cycle-time estimates
- Gate, runner, and vent strategy
- Written report with annotated screenshots
Typical applications
- New product introduction
- Cost-reduction redesign
- Problem-part recovery
- Transfer tooling from overseas
Equipment
- SolidWorks
- Fusion 360
Standards
- Feedback cycle ≤ 5 business days
Lead time
Service-level windows
StageStandardExpedite
StageInitial markup (< 20 features)Standard3–5 business daysExpedite48 h
StageFull review (complex part)Standard1–2 weeksExpedite5 business days
StageFollow-up revisionStandard2–3 business daysExpedite24 h
Expedite windows subject to load. Confirm on quote.
Accepted file formats
STEP AP203/214/242Parasolid (x_t)Native SolidWorks (.sldprt / .sldasm)Fusion 360 (.f3d / STEP export)PDF drawings
Materials routinely run · —
FM.006Mold-flow simulationPre-tool validation——
Mold-flow simulation
Mold-flow simulation predicts fill, pack, cool, and warp before tool steel is cut. Results drive gate placement, runner sizing, and cooling strategy decisions with data, not guesswork.
Key features
- Fill, pack, warp, and fiber-orientation analysis
- Conformal cooling feasibility
- Weld-line and air-trap prediction
- Material-database-backed runs
- Annotated PDF report with recommendations
Typical applications
- Thin-wall and long-flow parts
- Glass-filled warp-critical geometry
- Multi-gate balance studies
- Validation of DfM changes
Equipment
- Mold-flow simulation suite
Standards
- Reports delivered in PDF and native project formats
Process window
Machine and cycle limits
ParameterMinMaxUnitsNotes
ParameterFill analysisMin—Max—Units—NotesIncluded
ParameterPack / hold analysisMin—Max—Units—NotesIncluded
ParameterCooling analysisMin—Max—Units—NotesIncluded (baffle, bubbler, conformal)
ParameterWarp predictionMin—Max—Units—NotesIncluded
ParameterFiber orientation (filled resins)Min—Max—Units—NotesIncluded
ParameterWeld-line / air-trapMin—Max—Units—NotesIncluded
ParameterMaterial databaseMin—Max—Units—NotesStandard library + supplier-supplied .mtr files
Lead time
Service-level windows
StageStandardExpedite
StageSingle-gate fill studyStandard3–5 business daysExpedite48 h
StageMulti-gate balanceStandard5–7 business daysExpedite3 business days
StageFill + pack + warp (full cycle)Standard1–2 weeksExpedite1 week
StageDoE (multiple gate / cooling variants)Standard2–3 weeksExpedite1–2 weeks
Expedite windows subject to load. Confirm on quote.
Accepted file formats
STEP AP203/214/242 (part and mold tool)Parasolid (x_t)Native mold-base assembly.mtr material files from supplierPDF report delivery + native simulation project archive
Materials routinely run · —
FM.007Tolerance stack analysisWorst-case / RSS——
Tolerance stack analysis
Worst-case and RSS tolerance stacks on multi-component assemblies. Output identifies the tolerance drivers you can relax without affecting function — and the ones you cannot.
Key features
- 1D linear worst-case and RSS stacks
- GD&T interpretation
- Sensitivity ranking of contributing dimensions
- Capability (Cpk) target alignment
- Recommended GD&T edits returned on drawing PDFs
Typical applications
- Mating micro-assemblies
- Snap-fit and press-fit joints
- Sealing interfaces
- Mechanism clearance budgets
Equipment
Standards
- ISO 2768 supported
Process window
Machine and cycle limits
ParameterMinMaxUnitsNotes
Parameter1D linear stackMin—Max—Units—NotesUp to 100 contributing dimensions
ParameterGD&T interpretationMin—Max—Units—NotesISO 2768 / ISO 8015 supported
ParameterSensitivity analysisMin—Max—Units—NotesPareto ranking of contributors
ParameterCp / Cpk targetingMin—Max—Units—NotesRecommended tolerance bands returned
Lead time
Service-level windows
StageStandardExpedite
Stage1D stack (< 10 contributors)Standard2–3 business daysExpedite24 h
Stage1D stack (10–100 contributors)Standard5–7 business daysExpedite3 business days
StageIteration after drawing editsStandard2–3 business daysExpedite24 h
Expedite windows subject to load. Confirm on quote.
Accepted file formats
STEP AP214/242 assembly (preferred)Native SolidWorks assembly (.sldasm)PDF drawings with GD&TBOM / item master optional
Materials routinely run · —
FM.008First-article inspectionOGP G45 SmartScope(1.5 + L/200) µm E2All materials
First-article inspection
Multi-sensor first-article inspection on an OGP SmartScope G45 combining video, touch, and optional laser measurement. Full GD&T evaluation with reports delivered in customer-specific formats.
Key features
- Video with AccuCentric zoom, TP20 touch probe, optional laser
- CNC routine capture for repeat inspection
- GD&T evaluation
- Temperature-controlled lab at 20 ±1 °C
- Traceable to NIST via calibrated gauge blocks
Typical applications
- First-article inspection submissions
- Dimensional capability (Cpk) studies
- Supplier part qualification
- Audit-ready measurement records
Equipment
- OGP SmartScope G45 (video + TP20)
- Calibrated gauge-block stack
- Surface profilometer (partner)
Standards
- NIST-traceable metrology
- ISO 9001:2015 quality system
Process window
Machine and cycle limits
ParameterMinMaxUnitsNotes
ParameterMeasurement envelopeMin—Max450 × 450 × 200UnitsmmNotes—
ParameterVolumetric accuracy (E2)Min—Max(1.5 + L/200)UnitsµmNotesPer ISO 10360-7; L in mm.
ParameterVideo resolutionMin0.1Max—UnitsµmNotesSub-pixel edge detection.
ParameterMin feature size (video)Min0.010Max—UnitsmmNotes—
ParameterWorking distanceMin90Max—UnitsmmNotes—
ParameterMax part weightMin—Max40UnitskgNotes—
Tolerance capability
Achievable tolerances by feature class
All tolerances verified on a temperature-controlled OGP SmartScope G45. Advanced values require dedicated setups and additional inspection time.
FeatureStandardAdvancedInspection methodNotes
FeatureLinear (< 50 mm)Standard±1.5 µmAdvanced±1 µmInspection methodVideo / TP20NotesAdvanced requires Masterprobe + lab-stabilized setup.
FeatureLinear (50–200 mm)Standard±2.5 µmAdvanced±1.5 µmInspection methodTP20 touch probeNotes—
FeatureDiameter (< 5 mm, video)Standard±1.0 µmAdvanced±0.5 µmInspection methodVideo edgeNotes—
FeatureDiameter (5–25 mm, touch)Standard±1.5 µmAdvanced±1 µmInspection methodTP20Notes—
FeatureFlatness (over 50 mm)Standard2 µmAdvanced1 µmInspection methodTP20 multi-pointNotes—
FeaturePosition (true position)Standard±2 µmAdvanced±1 µmInspection methodVideo + TP20Notes—
FeatureSurface roughnessStandardNot in-houseAdvanced—Inspection methodPartner profilometerNotesSub-contracted when Ra is spec-bearing.
Lead time
Service-level windows
StageStandardExpedite
StageSimple FAI (< 10 dims)Standard3–5 business daysExpedite48 h
StageComplex FAI (10–50 dims)Standard1–2 weeksExpedite1 week
StageFull FAI report packageStandard2 weeksExpedite1 week
StageCapability study (Cp/Cpk, 30 pcs)Standard2 weeksExpedite1 week
Expedite windows subject to load. Confirm on quote.
Accepted file formats
STEP AP203/214/242 for CNC program generationPDF drawings with bubbled featuresNative CAD for GD&T datum interpretationExcel / PDF report delivery
Materials routinely run · All materials
Machine not listed?
We take on weird geometry. If it is measured in microns and needs to be made twice, talk to us.
Submit a printMaterials · 12 alloys & polymersOpen the materials library
Materials we run.
Molded resins
- PEEK
- LCP
- COC
- Ultem (PEI)
- PC
- ABS
- PPSU
Machined metals
- 316L SS
- 17-4 PH SS
- Ti-6Al-4V
- W-Carbide
- Inconel 625/718