Injection molded plastic parts for demanding applications

As an engineering partner for high precision plastic and injection molding solutions, we are constantly working with our customers to meet new challenges, develop solutions and open up new areas of application.

Our injection molded products are used in both mechanical engineering and the automotive industry, and likewise in medical technology, aerospace, renewable energy, semiconductor technology and electronics. Among other things, they replace metal components, reduce weight, improve friction, sustainability and efficiency. They extend service life and reduce costs for the user.  

Additionally, we also aim to set new standards in technological solutions by identifying trends with market potential and customer benefits at an early stage, and translating them into innovative new developments. Our innovation focus is on sustainability and intelligent plastics solutions. 

We are your solution partner for your individual and application-specific requirements. In addition to custom injection molding, we offer outstanding technical support combined with a variety of manufacturing processes, including in-house material development, compounding, CNC machining and a wide range of finishing and assembly solutions.  

Replace metal with high performance plastic injection molds

With our wide range of high performance plastics (e.g. PEEK or PPS compounds), we offer a strong alternative to metal in many industrial applications where lightweight construction and energy-efficient solutions are required.

Plastic injection molding solutions can integrate additional functions, reduce assembly costs, optimise lubricants and improve sustainability. 

Our competencies include: 

  • Development of highly filled application-specific plastic compounds or material selection. 
  • Development of custom injection molded components to replace metal products 
  • Production of complex geometries and integration of functions 
  • Reduced C02 footprint 
  • Use of recycled materials
  • Lower operating costs due to weight benefits
  • Overmolding of components (e.g. bushings / axles / plates) 


Optimising friction, efficiency and running conditions with injection molded components

Tribology, sliding and friction applications play an important role in many products, especially in industrial applications such as drives, pumps, vehicles, e-mobility or aerospace.

Our injection molded parts made of high performance plastics, such as seals, gears, bearings and bushings, improve running conditions, energy and CO2 efficiency. We also achieve high wear resistance and reduce noise and vibration. Molded parts made from optimised plastic injection molding compounds, PTFE or inorganic solid lubricants extend emergency running properties and reduce the use of lubricants in the application.

Our full-service range of support in the development of special materials, product development and innovative processing technology enables sustainable injection molded parts that help our customers reduce the environmental footprint. 


Example: Drive train components

  • High energy efficiency
  • Long component life
  • High temperature resistance
  • Good thermal conductivity
Piston Sleeve

Example: Components in axle and steering systems

  • Improved running smoothness
  • Uniform starting characteristics
  • Less wear
  • Lower weight
  • High bending strength 

Example: Thrust washers

Injection molded thrust washers from Ensinger are primarily used in high wear or oil-free sliding applications such as axle assemblies, engines, gearboxes, pumps, power take-offs and clutches. They are designed for applications where axial space and maintenance are limited.

Advantages of Ensinger thrust washers:

  • Versatile shaping
  • Material optimisation and development
  • Frictional testing

Example: Piston rings

A characteristic feature of injection molded piston rings is an opening in the ring and a defined, non-cylindrical shape when not installed. Piston rings do not take on a circular shape when until they are pressed into the assembled condition. 

Depending on the required modulus of elasticity, mechanical strength and abrasion resistance, rectangular sealing and piston rings are developed from individually modified high temperature plastics to ensure optimisation of the dynamically rubbing machine parts.

Advantages of Ensinger piston rings:

  • Application-specific designs and lock geometries
  • Wear-optimised materials
  • Special Ensinger compounds
  • Leakage testing 

Injection molded assembly solutions

Example: Insert & Overmolding 

With the multi-component processes, such as 2K or overmolding of inserts, we can produce the optimum component for you, both economically and functionally.
By combining materials and interlinking processes, additional or subsequent manual operations can be avoided.

  • Functional integration
  • High-precision injection molding
  • Combination of different plastic materials, e.g. colours
  • Integration of inserts made of different materials
  • Application-specific injection molding material selection and material development
rotary vane

Example: Assembled functional injection molded parts

We develop and manufacture ready-to-install complex assemblies for industries such as automotive, medical, aerospace and mechanical engineering.
For these demanding applications, we guarantee functionality and design the application-specific molded parts that take into account and compensate for all assembly-specific tolerances.

  • Certified and qualified suppliers for components (metal parts, etc.)
  • CNC machining 
  • Wide range and expertise of assembly processes for best efficiency and performance
  • Ultrasonic welding
  • Laser marking, printing
  • Inspection and functional testing (e.g. inline leak test)
Check valve

Injection molded solutions for medical technology

We have been developing medical components and instruments for many years.

We offer solutions using customised medical grade injection molding material from both engineering and high performance plastics, depending on the requirements. 

Example: Molded & assembled torque spanner for dental applications

  • Steam sterilisable
  • High dimensional stability
  • Chemical resistant
  • Assemblies
  • FDA and USP compliant

Example: Surgical instruments

Many medical devices such as surgical instruments are re-used after intensive cleaning, disinfection or sterilisation. Our solutions include: 
  • Application-specific material design for
    • Chemical resistance
    • Sterilisation resistance
    • Durability
    • Load and temperature requirements
    • Mechanical requirements
  • Overmolding, assembly and marking
  • High surface quality
  • Burr-free

Example: Injection molding for medical diagnostic systems

In computer tomography (CT), two X-ray sources rotate around the patient at high speed. These key components are mechanically supported and mounted by Ensinger components made of TECAPEEK, which can absorb centrifugal forces of up to thirty times the acceleration due to gravity.
The near-net-shape blanks are produced without cavities and with large wall thicknesses using injection molding. CNC machining is used to machine the joint and internal surfaces and to finish the surface finish, while final assembly and testing complete the work. To ensure quality and conformity, we also use non-destructive testing methods.
By using an injection-molded blank, we can greatly reduce the amount of PEEK material used, keep CNC machining to a minimum and significantly reduce the overall costs for our customers. The whole process helps to conserve resources and protect our environment.
  • Injection molded near-net-shape blank
  • CNC milling with precise tolerances
  • Saving material and costs
  • Material with long-term resistance to X-rays
  • High service temperature of 260 °C
  • Non-destructive testing methods
Guiding Part

Striving for innovation


Microsystems play an essential role in numerous applications, for example in the automotive sector, in medicine, communication or in the energy industry. 
Currently however, complex and costly production processes in cleanroom environments, expensive machinery and complex process steps present manufacturers with major challenges.

With injection-molded microsystems, Ensinger offers a completely new approach here. 
The innovative manufacturing process significantly reduces the required process steps. We combine many years of injection molding experience, an in-depth understanding of the individual components and innovative manufacturing methods - for quality at the highest level. 
Advantages of Ensinger wafers for microsystems:

  • Wafers with high molding accuracy and flatness
  • High degree of customisability according to customer requirements
  • Production without toxic chemicals
  • No lithography necessary
  • Production completely without clean room environment
  • Resource-saving production
  • Production of individual microsystems on the wafer possible

Fuel Cell Materials and Fabrication

PEMFC components


Fuel Cell Materials and Fabrication

Hydrogen fuel cells are regarded as highly efficient power generators that produce/generate electrical energy by reversing water electrolysis. Due to their low emissions and good efficiency, there are numerous international efforts to further develop fuel cell technology. The Polymer Electrolyte Membrane Fuel Cell (PEMFC) is often the focus of these efforts. Ensinger offers proven materials and processing methods for such PEMFC components.


Innovative photovoltaic mounting system for flat roofs elevation made of engineering plastic

BASF, Goldbeck Solar and Ensinger have jointly developed a modular mounting system for flat-roof solar installations in which the load-bearing elements are made of a BASF engineering plastic for the first time. The lightweight material used comes from BASF's polyamide range.
One of the main advantages of the new supporting elements made of the application-optimised thermoplastic is that the roof is not penetrated or the roof cladding damaged during installation.
In addition, Ensinger was able to make use of the possibilities offered by the injection molding of thermoplastics and integrate numerous functions into the plastic construction in just one manufacturing process:

  • Snap joints
  • Ribbing
  • Recesses for water drainage
  • Cable routing

Until now, the substructures of photovoltaic systems on flat roofs have mainly been made of steel and aluminium. The new system consists of easy-to-install, lightweight plastic support elements and sheet metal moldings that are gentle on the roof.

The material used is ideal suited for outdoor use because it has a very low creep tendency even at high temperatures (up to 80 °C) and has exceptional toughness and rigidity even at low temperatures of up to -30 °C. In addition, the highly glass fibre reinforced plastic support elements and sheet metal molded parts are also UV and weather resistant. A computer simulation tool has been used to optimise the components for photovoltaic-specific requirements such as snow and wind loads.