Near-Net-Shape manufacturing of plastic parts

At Ensinger, the manufacture of Near-Net-Shapes, also know as "close-to-contour manufacturing", is a key approach for producing complex components made of high-performance plastics in a resource-efficient and economical way. During production, the blank is given a shape that is almost identical to the final contour, meaning, the result being that only a few minor machining steps are required to meet the final specifications.
Ensinger manages the entire process chain — from developing and manufacturing the material, to producing the Near-Net-Shape blanks, and then on to final machining.

This approach endeavors to reduce material usage and processing costs, shorten production times, and increase overall manufacturing efficiency in a sustainable way. Near-Net-Shape technology is particularly advantageous for combining complex geometries with high-performance plastics, such as PEEK and thermoplastic fibre composites, which are used in the medical technology, aerospace and the semiconductor industries.

Precision plastic components can be manufactured more efficiently using Near-Net-Shape technology, which offers several advantages.

Ensinger can manufacture Near-Net-Shape parts from high-performance engineering plastics using injection molding, compression molding, or press sintering (direct forming process). Subsequent final processing, such as cutting threads, drilling holes, or milling to size, can also be carried out in-house. Thus, Ensinger offers a resource-efficient, economical, high-performance solution that replaces complex, costly processes and enables the production of complex geometries.

The blank is injection molded with Near-Net-Shape accuracy, and then machined according to the specifications required. This process enables the creation of complex structures and undercuts that would not be technically feasible using injection molding alone. A comparison shows that combining injection molding and machining results in a more economical, optimised component design than the original machined plate.

Near-Net-Shape compression molding is used to produce thermoplastic composite preforms. First, plastic-coated fiber mats, known as semipregs, are cut to size and placed in the mold. Then, they are consolidated and impregnated.
This process is ideal for producing highly stressed, complex, or three-dimensionally curved components that would otherwise require time-consuming milling from fiber-reinforced plates. Near-Net-Shape manufacturing significantly reduces material usage. Unlike milling from a composite plate, Near-Set-Shape compression molding allows the fibers to be laid in the mold along the defined direction of force. This allows the mechanical reinforcement to be precisely tailored to the expected load patterns during use. These customised composite components are used in medical technology, mechanical engineering, sports, and aerospace.

In the direct forming technology for Near-Net-Shapes, the preforms are made from high-temperature polyimide (PI) plastic.
The powdered material is pressed into blanks that closely match the final shape, which are then sintered. This process can be used to produce parts that have to withstand high mechanical or thermal loads.
Subsequent processing, such as finishing or precise milling, can be carried out at Ensinger or your location. This allows for the realisation of material- and time-efficient solutions that are precisely tailored to demanding applications.