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Cleanroom Injection Molding

Overview

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At HiCOMP Cleanroom Injection Molding, we offer high-quality, precision products that meet the strictest quality standards.

 

Our cleanroom facility is ISO 7 rated, ensuring a sterile and controlled environment for manufacturing products that meet your exact specifications. Our skilled professionals use advanced technology and rigorous quality control procedures to provide you with the best possible service. Let us be your partner in producing high-quality, sterile products that meet the highest standards of cleanliness and hygiene.

Workflow

01

Receive Product Drawings and Specifications

04

Optimize Molds and Injection Molding Process

02

Conduct DFM (Design for Manufacturing) Analysis

05

Define SOP for Injection Molding Process and Quality Standards

03

Design and Manufacture Molds

06

Initiate Mass Production

Technologies & Processes

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HiComp has developed a wide range of molds for various applications, including precision microfluidic chips for Single-cell Sequencing, Direct Elisa, and Flow Cytometry.

 

We also specialize in molds for life sciences consumables, such as 96-well and 384-well plates. With over 500 successful customer projects completed, HiComp is a trusted partner in providing high-quality, tailored molding solutions.

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Key Categories of Mold Manufacturing

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Single-cavity or multi-cavity molds

Single-cavity molds are suitable for small-batch production or product process testing, while multi-cavity molds are ideal for large-scale production. The image shows the mold for PCR tubes, which is designed for scale-up manufacturing.

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Precision molds

Precision molds are used for channel dimensions smaller than 100 µm, with strict requirements for surface roughness of channels or chambers. Such molds are generally produced using high-precision CNC machines to process metal molds. For finer features below 5 µm, HiComp employs its proprietary MEMS mold fabrication technology.

Key Advantages of HiComp Injection Molding

  1. Precision Molds: Minimum feature size down to 2.5 µm using MEMS and high-speed CNC technologies (beyond conventional CNC metal molds).

  2. Cleanroom Injection Molding: ISO 7(Class 10000) facility, with localized ISO 6(Class 1000) environments for higher cleanliness needs.

  3. Integrated Solutions: Seamless connection of molded products with downstream processes such as bonding, surface functionalization, reagent storage & lyophilization, and assembly & automation.

Clean Room Gallery

Materials & Capabilities

Injection Molding Materials

injection molding specs

Process Capabilities

injection molding specs

Case Studies

24-Well Open-Bottom Plate for Optical Assays

Design-for-manufacturing optimization for precision biological devices with glass integration​

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Draw Angle Check

24 well filling analysis

Filling Analysis

Customer Challenge

  • Open-bottom 24-well plate requiring thin optical interface compatibility

  • Risk of sink marks from thick wall regions

  • Tight dimensional control for glass bonding alignment

  • Need to ensure uniform filling without short shot

  • Weld lines and air traps expected due to multi-cavity geometry

Engineering Approach

  • Optimized wall thickness distribution to reduce shrinkage defects

  • Increased draft angles (1.5° → up to 5°) for reliable demoldingAdded locating features for glass alignment and assembly

  • Designed four-point gate cold-runner system for uniform filling

  • Verified moldability using Moldflow simulation: no short shot detected, controlled shrinkage (~0.74%), deformation <0.32 mm

Manufacturing Outcome

  • Material: GPPS (SECCO GPPS123 equivalent)

  • Part volume: 53 g

  • Cycle time: ~50 s

  • Mold: three-plate tooling (S136 steel)

  • Machine: 100-ton injection platform

  • Tool lifetime: 100,000 shots

  • Surface finish: Ra ≤ 0.02 achievable

  • Gate vestige controlled <0.25 mm

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