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Thermoplastic injection moulding

Injection moulded parts made from high-performance plastics

We are your partner for the development of your individual injection moulding solutions and the production of high precision plastic injection moulded parts for demanding applications in a wide range of industries such as medical, automotive, aerospace and many more.

Combining extensive plastics and engineering know-how with the highest levels of expertise in technical injection moulding processes, we offer customised solutions through our comprehensive portfolio of high-performance polymers and complementary, value-adding processing methods

What sets us apart: 

  • Precision injection moulding in series production: Fully automated manufacturing with state-of-the-art machinery
  • Engineering expertise: In-house development, simulation and toolmaking
  • Material diversity: Access to over 100 modified thermoplastics – including compounds developed in-house for thermoplastic injection moulding and thermoplastic moulding 
  • Certified quality: ISO 13485, IATF 16949, ISO 9001 
  • Global presence: Production capacities in Europe, North and South America, and Asia 
  • Sustainable thinking: Recyclates, bioplastics, and a commitment to the circular economy 
  • The reliability of a family-owned company: Long-term, partnership-based, responsible

MORE THAN STANDARD: OUR PROCESSES FOR DEMANDING COMPONENTS 

Not every application can be solved with classic injection moulding. That is why Ensinger also offers a range of specialised manufacturing processes that enable us to produce complex, multifunctional or high-precision plastic components economically – even in series production. 

Insert moulding – plastic meets metal

Overmoulding – two in one step 

MuCell® process – lightweight + structure 

Injection-compression moulding – accuracy for flat components 

Micro injection moulding – precision in the millimetre range 

These technologies give you greater design freedom and open up new applications.

As an experienced injection moulding supplier to OEMs, we actively contribute to improving the function, quality and cost-effectiveness of your components with our diverse processes and targeted component optimisation. Ensinger processes over 100 thermoplastic materials, including high-performance plastics such as PEEK, PPS, LCP and PPA, as well as modified and fibre-reinforced compounds for increased rigidity and dimensional stability.  

Our team of experts will be happy to advise you on which process offers the best solution for your requirements.

HIGH PRECISION INJECTION MOuLDING – ENGINEERING SUPPORT FOR COMPLEX PLASTIC COMPONENTS 

Ensinger is your global technology partner for precise plastic injection moulding parts with tight tolerances and complex geometries. As a specialist in precision plastic injection moulding, we combine high-performance plastics with in-depth process knowledge and qualified engineering support – from the initial CAD model to certified series production. 
Thanks to our process-reliable manufacturing, even very tight tolerances and specifications can be reliably met (dimensional tolerances < 0.02 mm). 

  • Engineering expertise for microscopic tolerances 

    Our core competence lies in the implementation of components with tolerance-critical geometries, tight dimensional specifications (< ± 0.02 mm) and functionally integrated surfaces. In co-operation with our customers, we carry out
    • Tolerance analyses based on FMEA and CpK values 
    • CT-supported component testing 
    • Material selection based on mechanical, thermal and chemical performance (materials for injection molding) 
    • Simulation-supported tool concepts (e.g. Moldex 3D, FEM) to reduce warpage, weld lines or air pockets
    By using materials such as PEEK, PPS, LCP or PPA, we ensure dimensionally accurate performance – even in high-temperature applications, medical technology or demanding structural components. 

  • Design for manufacturing (DfM) – component optimisation right from the start 

    We support customers with DfM analyses right from the design phase in order to combine functional requirements with reliable manufacturing: 
    • FEM calculation 
    • Optimisation of wall thicknesses and flow paths to reduce filling differences 
    • Defined venting concepts to prevent flash 
    • Draft cores for demolding undercuts and claws/clips, threads 
    • Multi-component solutions (overmoulding) and insert molding for functional embedding 
    This early-stage consulting reduces changes in toolmaking, lowers part costs and accelerates time-to-market. 

  • Measurement technology & quality assurance at series-production level 

    We rely on a comprehensive QM system for the validation of dimensionally critical components: 
    • Optical and tactile 3D coordinate measurement technology 
    • Contour measurement, roughness analysis, component CT 
    • Component-specific tests according to customer requirements or ISO 13485 / IATF 16949 
    • Validation documentation according to APQP, PPAP, IQ/OQ/PQ
    • Tensile and compression tests 
    • DSC and TGA analyses 
    All production steps are carried out under SPC control – tailored to your regulatory requirements. Traceability is always guaranteed. 

THE FULL ENSINGER INJECTION MOuLDING RANGE 

Engineering expertise at Ensinger: Technically ahead of the curve 

At Ensinger, material, product and process development are integrated from the outset – for precise, economically viable and technically sophisticated plastic solutions. Through structured project management, modern simulation tools, reliable tool transfer and broad injection moulding manufacturing expertise, we efficiently bring innovations into series production. 
More about our engineering expertise

After manufacturing: added value through post-processing

Ensinger also offers comprehensive expertise after injection moulding: with CNC machining, surface finishing, laser marking and end-of-line testing, we ensure maximum quality and functionality. Whether moisture conditioning, tempering or assembly – our processes get your components into top form. 
 
More about our after-manufacturing processes

Thermoplastic materials: A broad portfolio

Choosing the right plastic is crucial for the function, service life and manufacturability of a component. Ensinger processes a wide range of thermoplastic materials – from engineering plastics to high-performance polymers – precisely tailored to the requirements of your industry. 
Thanks to our connection to Ensinger compounding, we also offer you the option of processing customer-specific modified materials – for maximum functionality and cost-effective series production. Among others, we use: 

  • High-performance plastics such as PEEK, PPS, LCP or PPA – ideal for applications with high thermal, chemical or mechanical loads. 
  • Fibre-reinforced compounds with glass or carbon fibres to increase rigidity, strength and dimensional stability. 
  • Tribologically, mechanically, electrically or otherwise optimised designs as well as material-specific special compounds 
  • Special materials for industries such as medical technology (e.g. ISO 10993-compliant) or electronics (e.g. halogen-free, UL94-certified). 
To our material overview

FROM IDEA TO SERIES PRODUCTION – AN OVERVIEW OF THE ENSINGER INJECTION MOuLDING PROCESS 

A successful plastic component starts with the right process. 
At Ensinger, we support your development every step of the way – with technical advice, in-depth material knowledge and modern project management. Our offering goes far beyond mere manufacturing: we deliver solutions – comprehensive, structured and transparent. 

1. Project clarification & consulting 

We analyse your mechanical, thermal, chemical and economic requirements. We advise you on materials for injection moulding and provide initial recommendations for component design – always with an eye to function and cost-effectiveness.  

2. Construction & design for manufacturing (DfM) 

We actively support you in the production-oriented design of your component. Early communication helps us avoid corrective loops later on. On request, we carry out filling simulations (Mouldex 3D) to minimise risks in advance.  

3. Tool development & construction

Tool construction takes place either in-house or in close co-operation with long-standing partners. We guarantee maximum precision, short lead times and close coordination throughout the entire tool realisation process. 

4. Sampling & approval 

After tool acceptance, initial sampling takes place under series-production conditions. We create test reports and document the results in accordance with your specifications – e.g. according to VDA, PPAP or customer-specific standards.  

5. Series production & quality assurance 

Our international production sites work according to the highest quality standards – IATF 16949, ISO 13485 or ISO 9001. Production is automated, documented and traceable. Clean-room production is also available on request.  

6. Logistics & global supply 

Whether just-in-time, kanban or decentralied delivery: with our plastic injection moulding sites in Germany, the USA, China and Brazil, we can supply customers worldwide flexibly and reliably – and manufacture locally if required. 

ENSINGER QUALITY IN INJECTION MOuLDING – RELIABLE, WORLDWIDE, CERTIFIED 

Ensinger sets the highest standards for quality, safety and traceability throughout the entire life cycle of an injection moulded part. The quality management system (QMS) is established worldwide at all locations (Germany, USA, Brazil, China) and certified according to ISO 9001:2015. Ensinger also complies with industry-specific standards such as ISO 13485 (medical technology), IATF 16949 (automotive), AS9100D (aerospace) and other specific standards. 
In practice, Ensinger relies on automated in-line testing processes and a comprehensively equipped measuring laboratory with, among other things, tactile 3D measuring machines, contour measurement, roughness analysis and special tests. 
Quality begins with design. FEM analyses, filling and process simulations as well as FMEA are used as early as the development phase to identify and avoid risks at an early stage. The entire product development process complies with standards such as APQP and PPAP. 

Your partner for injection moulding solutions

Your injection moulding development partner

Technical advice and support, innovative strength and the highest quality standards are our basis for successful long-term customer relationships. As a medium-sized injection moulding manufacturer, we combine extensive experience with high-tech and the highest solution orientation.

One-stop shop – injection moulding and more

In addition to first-class technical support for your project, we can offer you our own material development with in-house compounding, a combination of different production methods in injection moulding, CNC machining as well as assembly and finishing processes and much more. 

Responsibility: Resources and environment

Sustainability in injection moulding is a key factor for our long-term success. It ranges from the use of innovative materials, recyclates and renewable raw materials to closed-loop material cycles and the development of state-of-the-art recycling technologies. In addition, we offer a material-saving design for your injection moulded parts combined with environmentally friendly production.

OUR INJECTION MOuLDING LOCATIONS

Germany

About Ensinger GmbH

We are your partner for the development of your individual injection moulding solutions and the production of high precision plastic injection moulded parts for demanding applications in a wide range of industries such as medical, automotive, aerospace and many more. Combining extensive plastics and engineering know-how with the highest levels of expertise in technical injection moulding processes, we offer customised solutions through our comprehensive portfolio of high-performance polymers and complementary, value-adding processing methods.

USA

Brazil

China

Industries

Are you looking for a development partner who is on the same wavelength as you – globally accessible and with a family-oriented mindset?

Let us work together to bring your component to series production.

Contact us now