Xplore DSM Micro Injection Molding System Xplore 12mL

Overview

The Xplore DSM Micro Injection Molding System (Model Xplore 12mL) is a benchtop-scale, precision-engineered injection molding platform designed for R&D laboratories in polymer science, formulation development, and advanced materials testing. Operating on the fundamental principles of thermoplastic melt processing—namely, controlled plasticization, precise metering, high-pressure injection into a temperature-regulated cavity, and pressure-hold solidification—the system enables reproducible fabrication of micro-scale test specimens from as little as 0.1 g to full 12 mL cavity volumes. Its compact footprint (84 × 33 × 32 cm) and modular architecture allow seamless integration into fume hoods or standard laboratory workbenches, eliminating the need for dedicated production-floor infrastructure. Unlike conventional industrial injection molding machines, the Xplore 12mL system prioritizes experimental flexibility, material conservation, and thermal process fidelity over throughput—making it ideal for screening novel biopolymers, conductive composites, medical-grade resins, and other high-value formulations where gram-scale material availability is constrained.

Key Features

• Modular, fully detachable injection unit with air-driven piston actuation—enabling direct manual loading of powders, granules, or pre-compounded melts without screw feeding
• Split conical mold design integrated with a thermostatically controlled mold protection chamber; mechanical interlock prevents injection unless chamber is fully closed, ensuring operator safety and eliminating melt splatter
• Dual-zone independent heating control (2 × 1 zones) with maximum operating temperature of 400 °C, supporting high-melt-temperature engineering thermoplastics (e.g., PEEK, PEI, PSU)
• Precisely programmable hold pressure and dwell time—critical for minimizing post-mold shrinkage and dimensional variance in tensile bars, impact specimens, and microfluidic prototypes
• Integrated cooling module enabling mold temperature control down to sub-ambient levels (e.g., 15 °C), facilitating crystallinity studies and cycle-time optimization for semi-crystalline polymers
• Rapid nozzle heating (< 8 min from 20 °C to 240 °C) via cartridge heaters with PID feedback, minimizing thermal lag during multi-material trials
• Maximum clamping force of 18,000 N ensures cavity integrity even at elevated melt viscosities and high injection speeds

Sample Compatibility & Compliance

The Xplore 12mL accommodates a broad spectrum of thermoplastic and thermosetting systems—including commodity resins (PP, ABS, PS), engineering plastics (PA6, PC, POM), high-performance polymers (PEEK, LCP), filled composites (glass-, carbon-, mineral-filled), and bio-based matrices (PLA, PHA). Mold cavities are compatible with ISO 527-2 (tensile bars), ISO 179-1 (impact specimens), and ASTM D638/D256 geometries. All thermal and motion control subsystems comply with IEC 61000-6-2/6-4 electromagnetic compatibility standards. The system supports GLP-compliant documentation workflows when paired with optional audit-trail-enabled software modules, and its temperature calibration traceability aligns with ISO/IEC 17025 requirements for accredited testing laboratories.

Software & Data Management

The system operates via an embedded touchscreen HMI with intuitive step-based cycle programming. Users define up to 10 discrete stages per cycle—including plasticization time, injection speed ramp, hold pressure profile, cooling duration, and ejection delay—with real-time logging of temperature (±0.5 °C), pressure (±1.5% FS), and position (±0.02 mm). Process data export is supported in CSV and XML formats for integration with LIMS or statistical analysis platforms (e.g., JMP, Minitab). Optional Xplore Control Suite v3.x provides remote monitoring, multi-user role-based access control, electronic signature support per FDA 21 CFR Part 11, and automated report generation aligned with ASTM D3641 and ISO 294-4 reporting conventions.

Applications

• Rapid prototyping of micro-scale functional parts for feasibility assessment prior to tooling investment
• Formulation optimization of polymer blends, nanocomposites, and reactive systems under tightly controlled thermal histories
• Processing window mapping for new biodegradable or medical-grade resins under GMP-relevant conditions
• Correlation studies between rheological behavior (measured via parallel rheometry) and final part morphology (via SEM/DSC)
• Education and training in polymer processing fundamentals—demonstrating shear-thinning, melt fracture, weld line formation, and crystallization kinetics
• Supporting ISO 10993-12 extractables testing by generating standardized specimen sets from minimal raw material batches

FAQ

Can the Xplore 12mL be used without the Xplore Micro Twin-Screw Compounder?
Yes. While optimized for tandem operation with the Xplore 12cc twin-screw compounder, the micro injection molder functions independently for pre-compounded pellets, powders, or masterbatches.
What is the minimum recommended sample mass for reliable cavity filling?
For geometrically complex cavities, ≥0.3 g is recommended; for standard dogbone tensile bars, consistent filling is achieved from 0.15 g upward.
Is mold temperature control limited to heating only?
No. The integrated cooling module enables active temperature regulation from 15 °C to 400 °C, supporting both rapid quenching and isothermal crystallization protocols.
Are custom mold designs supported with validated thermal uniformity reports?
Yes. Xplore’s in-house mold design team delivers CNC-machined steel molds with thermal simulation reports and cavity temperature mapping (per ISO 294-4 Annex B) within 10–15 business days.
Does the system meet CE and UL safety certification requirements?
Yes. Fully certified to EN 60204-1 (electrical safety), EN ISO 13857 (safeguarding), and UL 61010-1 (laboratory equipment), with documented risk assessment per ISO 12100.