High precision Injection molding solutions

Injection molding services at Ensinger

Ensinger has decades of experience in the injection molding of high performance plastics and produces more than 50 million components ever year. With injection molding facilities in Germany, USA, Brazil and China, we offer a global presence to reliably serve your local markets. 

High-Tech Injection Molding

Our state-of-the-art injection molding facilities allow us to use the most appropriate equipment for your product and objective. From variable shot sizes and machine tonnages to different press types and automation - in the region where you need us. With our state-of-the-art equipment and ability to find the right machine for your part requirements, we are able to produce precision molds or molds with tight tolerances.  
Our custom injection molding services cover all aspects of this. Ensinger has a diverse range of equipment that provides our customers with the special features required for precise injection molding production, resulting in better product quality and performance.   
We are constantly expanding our manufacturing competencies through intelligent and forward-looking investment. 
Insert injection molding often involves combining metal and plastic parts into a single unit. By using high performance thermoplastics, the wear resistance or even the tensile strength is further increased and at the same time the weight is reduced compared to a pure metal component. 
Similar to insert molding, overmolding technology involves overmolding or backmolding parts. The first component can also be already injection molded or, for example, a composite component for the ultimate solution of lightweight construction and maximum strength. 
The multi component process, such as 2K molding (two shot molding), allows us to combine different plastic materials or colours and avoid linked processes, additional or subsequent manual machining or achieve functional integration. 
We are experts in injection molding parts with tight tolerances and the highest process reliability. Our injection molding machines are equipped with the latest measuring technology. The use of specific sensors, e.g. for cavity pressure, mould wall temperature or melt viscosity measurement, enables shot-by-shot online process control and online quality assurance. 
For MuCell® injection molding technology, we have our own injection molding plant. This injection molding technology is a physical injection molding foaming process for thermoplastics. In terms of quality, MuCell® parts are characterised by a higher dimensional stability than conventionally manufactured parts, while at the same time avoiding sink marks and reducing the weight of the moulded part. 

Optimal drying of the polymer for the injection moulding process is essential for high precision, high quality and reliably reproducible injection moulded parts made from high-performance or engineering plastics.

Our advanced material preparation systems ensure optimum drying of the material and the necessary residual moisture. They supply the injection molding machines fully automatically as a closed and monitored system. 

Broad spectrum of value-added services

No matter what challenge you set us, Ensinger has the experience, manufacturing processes and know-how to reliably produce the injection molded components you need from high performance and engineering plastics to the highest quality standards.

Among other things, we offer essential finishing options and value-added operations, such as: 

With special CNC lathes and CNC machining centres, Ensinger offers extensive finishing options, including turning, milling and drilling. Some injection molded parts require particularly tight tolerances or designs with undercuts that require additional CNC machining. Cobots or intelligent automation systems are also used for efficient operation and interlinking of the CNC machines. 

This enables our customers to source even the most complex parts from us economically and with maximum material savings.  For example, we can also produce a final product from a near-net-shape injection molding blank instead of machining it from a solid blank with a high material loss. 

We have extensive expertise in many different conditioning, surface treatment and marking processes to provide specific solutions to meet our customers' requirements. 


Customised conditioning of components, e.g. by tempering and annealing. This improves strength, chemical resistance and dimensional stability over a wide temperature range. 

Surface finishing techniques 

With various surface treatment and deburring technologies, e.g. efficient automated blasting processes, deburring technologies or vibratory grinding, we ensure that the required haptic and visual quality levels, appearance and safety standards are met.   

Marking technologies 

For traceability and customised product marking, we offer solutions such as printing, painting or laser marking, e.g. of a data matrix code. 

We manufacture complex assemblies and ensure functionality by matching the individual parts to each other, taking into account all assembly-specific tolerances. 

Ensinger offers a wide range of assembly and packaging technology, from manual to fully automatic. 

Depending on the requirements, assembly is carried out by overmolding already during the injection molding process or subsequently using advanced technologies, such as ultrasonic welding, but also automated press-fitting processes, such as an O-ring assembly with subsequent functional testing. 

Quality management and assurance

Quality assurance through a strong QMS 

Ensinger's Quality Management System (QMS) is based on recognised standards and includes important aspects such as statistical process control and a continuous improvement programme. Our QMS complies with the international standard for quality systems.  

We confirm these standards through internal and external audits and continuously develop our work processes.

All of our global injection molding sites in Germany, USA, Brazil and China are ISO 9001:2015 certified. 

In addition, our processes are tailored to the requirements of each industry. Our QMS is compliant with international standards and our injection molding sites are certified according to : 

We are committed to the highest quality, safety and traceability of our injection molded parts. Ensuring quality for our customers is a top priority in all areas of our business. Our injection molding and plastics manufacturing processes deliver high quality parts and assemblies for your business through the use of state-of-the-art measuring and control equipment, a fully implemented quality management system and appropriate inspection services. 
For medical applications, Ensinger ensures that customers receive comparable and approved plastics and also issues the relevant certificates of conformity for all medical materials. Our cooperating plants in Nufringen and Cham are qualified according to ISO 13485 and have clean room facilities. 
Our injection molding sites in Rottenburg, Germany and Shanghai, China, are qualified according to the international requirements of the automotive industry, IATF 16949.  
Our facility in Putnam, is certified to AS9100D, which ensures compliance with the highest aerospace and defense standards, as well as ITAR registered and NIST 800-53 compliant.

In-process measuring, testing and laboratory technology ensures product quality 

We also use fully automated optical inspection systems to monitor the injection molded parts during the production process. 

Our modern and extensive laboratory measuring equipment complements the quality assurance of our product. The systems and equipment we use include: 

  • Tactile 3D coordinate measuring machines
  • Tensile and compression testing machines
  • Contour scanners/ contour recorders
  • Roughness measuring devices
  • Other component-specific testing systems and measurements

Ensuring product quality starts at the design stage

Avoiding errors in the product development process is of particular importance.  As early as the design phase, we use tools such as FEM and Moldflow simulations to optimise and coordinate the product design and tool concept. Consistent application of product and process Failure Mode and Effect Analysis (FMEA) ensures that any effects on the product or application are identified at an early stage. Supplier development and close collaboration on purchased materials, including the necessary qualification, are also part of our product introduction process.  We also meet requirements such as APQP, PPAP or even certificates of conformity. 

Intelligent Automation

Automation systems are now considered indispensable in injection molding production because they help to improve part quality while maintaining quality, reduce material waste, lower labour costs and operate at consistent cycle times, thus reducing lead times.

We place particular emphasis on a balanced and intelligent level of automation to achieve both high efficiency and flexibility. This include the use of cobots.

In addition, we use automated handling systems such as six- or three-axis robot systems, multi-lift and articulated arm or universal robots for part removal, but also for inserting parts into the injection molding process. Intelligent interlinking with secondary operations such as CNC machining cells, milling units, assembly, finishing and testing units enables highly efficient production processes.

Strong capabilities for small series & prototyping 

For many application, e.g. for special industrial or medical products, we also produce small series using injection molding. We rely on efficient tool and mould concepts such as master mould concepts with mould inserts, and flexible automation solutions that support our employees in subsequent process steps. 
Technologies for the creation of test samples, such as 3D printing, complete our capabilities. 

Tool and mold making

In-house mold making and maintenance

High-performance injection molds and handling equipment are designed and manufactured in our in-house mold and tool making department with precision work on modern CNC machinery. In addition, our selected reliable external partners support us in meeting all customer requirements. 

Intensive series-accompanying and preventive maintenance of the injection molds by our mold specialists ensures consistent series quality of the injection molded parts, flexibility and fast response times.  

Tool expertise that convinces 

One of our core competencies is the design and construction of injection molds. Excellent tool expertise is the basis for top quality in the series production of injection molded components with the highest technical requirements.  
Our selected, reliable external partners also provide support to the satisfaction of our customers. 

Supply Chain Management

The right product in the right place at the right time

Thanks to a continuous material flow in our plants from the polymer to the finished part, our customers benefit not only from efficient processes but also from complete traceability along our value chain, i.e. from the production batch to the material batch.

Our material is conveyed to our injection molding machines in the right quality and in the right condition in a controlled manner or processed directly there. After the injection molding process and any finishing processes, reliable and partly automated packaging processes are used.

We use modern transport solutions such as driverless transport systems (AGVs) and innovative logistics concepts, EDI and ASN are also standard means of communication for us. 

Local and global supply

The global presence of our production and development sites enables us to offer our customers global availability. They benefit from local contacts and local production as well as central contacts and global coordination.