After manufacturing processes

From injection molded part to functional component

Injection molded components are usually ready for immediate use. However, in certain applications, specific post-processing may be necessary to create ready-to-install components that meet the requirements for functionality, dimensional accuracy, appearance and safety.
Ensinger offers a comprehensive range of such after manufacturing services – from CNC machining and surface finishing to assembly.
In addition, customer-specific end-of-line tests such as functional tests, leakage tests and camera-based quality controls can also be carried out.
This means our customers benefit from tested, ready-to-install components – with reduced coordination effort, minimized sources of error and greater process reliability in further processing.

Our capabilities include: CNC machining, Various Finishing options, Assemble and more.

1. CNC machining – precision made to measure

Many industries, such as aerospace and oil and gas, require extremely tight tolerances and geometries that cannot always be achieved by injection molding alone. Ensinger supplements the injection molding process with specialized CNC turning and milling centers for precise finishing options. This allows components with tight tolerances or complex geometries to be manufactured efficiently. Intelligent automation enables cost-effective processes – especially in the further processing of near-net-shape molded blanks with minimal material usage and reduced process costs.

2. Finishing – targeted refinement at all levels

Annealing -targeted reduction of stresses

During injection molding, rapid cooling and molding forces can cause internal stresses in the component.
These can impair dimensional accuracy and mechanical strength in later use. Annealing is an excellent method of reducing internal stresses and thus facilitating further processing.
In this process, the plastic component is heated in a controlled manner in an annealing oven and then cooled slowly.
Tempering homogenizes the distribution of stresses and increases crystallinity, both of which contribute to better dimensional stability and mechanical stability.
The process is particularly important for high-performance plastics such as PEEK or PPS, which must offer reliable material properties in demanding applications.
Utilizing our automated, accurate ovens, we can anneal your plastic shapes for you with ease.

Conditioning

Conditioning is a controlled process in which plastic components are stored under standard climate conditions (23°C, 50% relative humidity) until their weight stabilises. During this process, the material absorbs moisture until a stable equilibrium relevant to the application is achieved.
This is particularly important for hygroscopic materials such as polyamide, as they absorb moisture from the environment and can therefore change their properties.
The aim is to ensure the mechanical properties in later use.
The process is reversible and can be reversed depending on the conditions of use.

Heat staking

A thermoplastic peg, stud or boss is heated locally and mechanically formed. This creates a form-fitting connection that securely fixes components in place – for example, in O-ring assemblies or retaining elements. The process can be automated and is particularly suitable for series production.

Laser marking

Ensinger offers contactless laser marking for traceability or individual markings. Serial numbers, logos or codes are applied permanently, precisely and without additional materials directly to the component – even with complex geometries.

Surface finishing – for quality, safety and appearance

The surface of a plastic component plays a key role in its function, handling and appearance. To ensure that injection-moulded parts are burr-free, uniform and safe in use, Ensinger relies on proven processes for technical surface finishing. The aim is to reproducibly meet the desired requirements in terms of haptics, appearance, dimensional accuracy and safety – regardless of the number of parts or their geometry.
Various automated deburring and blasting processes (barrel finishing/vibratory finishing) are used, tailored to the material and component requirements. These processes are particularly efficient in series production and enable consistent quality without manual reworking.

Ultrasonic welding – joining without fasteners

Bonding polymers to each other or even to other substrates is often difficult. Our deep understanding of polymer make-up and physical characteristics allows us to maximize adhesion by means of surface preparation and process control. With ultrasonic welding, plastic parts are selectively heated by high-frequency vibrations and joined together without screws, adhesives or additional materials. The result: strong, clean connections for series-production assemblies.
Let us help with your next polymer bonding application

3. Assembly – from individual parts to functional units

Ensinger assembles plastic components into ready-to-use assemblies – either manually or fully automatically. Assembly-specific tolerances are taken into account right from the development stage to ensure subsequent functionality and a precise fit. Depending on requirements, assembly takes place directly during injection molding (for example by overmolding) or in separate steps. Whether you require bonding parts, installing threaded inserts, or complete bearing assembly, we can help with your assembly needs.

Contact us

As a one-stop shop in the plastics sector, Ensinger covers the entire value chain – from the development of a suitable material to the ready-to-install injection-molded part. We would be happy to advise you on your application. Individual solutions are developed for each application, achieving the best possible results in terms of functionality, appearance and economy.

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