Plastic injection molding

High-performance in series production

Injection molded parts made from high-performance plastics. Whether you need precise functional parts for medical technology, resilient components for aviation or complex geometries for mechanical engineering, we develop and manufacture custom injection molded parts from high-performance plastics that work where other materials reach their limits. 

As an internationally positioned family-owned custom injection molding manufacturer with over 50 years of experience, we accompany your product idea from the initial sketch to series production – in close co-operation, with a wealth of engineering expertise and a clear goal: the optimal solution for your application. 

We supply renowned OEMs with OEM injection molding solutions in a wide range of industries worldwide – including medical, aviation, industrial and automotive engineering – and have established industry-proven, standardized processes that ensure quality, traceability and efficiency along the entire value chain. 

With our injection molding factories in the USA, Germany, China and Brazil, we stand for quality, customer proximity and reliable series production worldwide – no matter where your project starts. 

What sets us apart: 

  • Precision injection molding 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 molding and thermoplastic molding 
  • 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 molding. That is why Ensinger also offers a range of specialized manufacturing processes that enable us to produce complex, multifunctional or high-precision plastic components economically – even in series production. 

Insert molding – plastic meets metal

Overmolding – two in one step 

MuCell® process – lightweight + structure 

Injection-compression molding – accuracy for flat components 

Micro injection molding – precision in the millimetre range 

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

As an experienced injection molding supplier to OEMs, we actively contribute to improving the function, quality and cost-effectiveness of your components with our diverse processes and targeted component optimization. Ensinger processes over 100 thermoplastic materials, including high-performance plastics such as PEEK, PPS, LCP and PPA, as well as modified and fiber-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 MOLDING – ENGINEERING SUPPORT FOR COMPLEX PLASTIC COMPONENTS 

Ensinger is your global technology partner for precise plastic injection molding parts with tight tolerances and complex geometries. As a specialist in precision plastic injection molding, 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 (overmolding) 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 MOLDING 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 molding manufacturing expertise, we efficiently bring innovations into series production. 

After manufacturing: added value through post-processing

Ensinger also offers comprehensive expertise after injection molding: 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. 
 

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. 
  • Fiber-reinforced compounds with glass or carbon fibers to increase rigidity, strength and dimensional stability. 
  • Tribologically, mechanically, electrically or otherwise optimized 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). 

FROM IDEA TO SERIES PRODUCTION – AN OVERVIEW OF THE ENSINGER INJECTION MOLDING 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 molding 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 (Moldex 3D) to minimize 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 molding 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 MOLDING – RELIABLE, WORLDWIDE, CERTIFIED 

Ensinger sets the highest standards for quality, safety and traceability throughout the entire life cycle of an injection molded 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 MOLDING SOLUTIONS 

Your injection molding development partner

Technical advice and support, innovative strength and the highest quality standards form the basis for our long-term successful customer relationships. As a medium-sized plastic injection molding manufacturer, we combine comprehensive engineering experience with high-tech injection molding and a consistent focus on solutions. 

One-stop shop – injection molding and more 

In addition to first-class technical support for your project, we offer our own material development with in-house compounding, the combination of different manufacturing methods in injection molding, and post-processing options such as CNC machining, assembly and finishing processes. 

Responsible towards resources & environment 

Sustainability in injection molding technology is a decisive factor for our long-term success. It ranges from the use of innovative materials, recycled materials and renewable raw materials to closed material cycles and the further development of state-of-the-art recycling technologies. In addition, we offer material-saving design of your custom plastic injection molding parts in conjunction with environmentally friendly production. 

OUR INJECTION MOLDING LOCATIONS

USA

About Ensinger Precision Components

Ensinger Precision Components is part of Ensinger GmbH with North American headquarters in Washington, PA. Ensinger’s North American operations focus on processing high-performance engineering plastics and expanding the market for engineering plastics with extrusion, casting, machining, compression, and injection molding expertise. We leverage our knowledge of high-performance polymers and applications to provide our customers with numerous options as they push the envelope of innovation and part design in their respective industries.

Germany

Brazil

China


Current topics

07. March 2025
Quality and precision are at the core of everything we do. To continue delivering the highest level of accuracy in part measurement, we’ve added the GLOBAL FX 9158 Coordinate Measuring Machine to our capabilities.
28. August 2024
ITAR registration and AS9100 certification are essential for companies that manufacture parts for the aerospace and defense (A&D) industries because they help ensure that products are safe and reliable and that national security is protected. Companies that comply with ITAR …
26. November 2024
Heat plays a pivotal role in injection molding. While it's understood that heat is required to melt and form plastic components, other less apparent uses are critical for producing functional, reliable components that meet specifications. To consistently mold high-quality components, …

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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.