Trade fair highlight 27. July 2026
Leonhardt e.K. introduces 3 mm collapsing core for next-generation micro injection molding
Hochdorf, Germany – At FAKUMA 2026, Leonhardt e.K. will present a major innovation in tool and mold making: a collapsing core with a diameter of just 3 mm. The new development pushes the limits of miniaturization in injection molding, enabling the economical production of highly precise plastic components with complex internal undercuts.
While conventional collapsing cores are typically available in diameters ranging from 8 to 240 mm, Leonhardt's 3 mm solution enables the demolding of internal undercuts of approximately 7% of the core diameter. This opens new possibilities for manufacturing miniature components with geometries that were previously difficult or impossible to produce in a single molding process.
The technology enables highly miniaturized plastic parts with integrated undercuts to be produced directly by injection molding. Secondary assembly and post-processing operations can be significantly reduced or eliminated, improving part quality, process reliability, and manufacturing efficiency while lowering production costs.
The innovation is particularly relevant for applications in medical technology, microfluidics, precision engineering, and microsystems technology. By integrating complex internal features directly into molded parts, manufacturers gain greater design freedom and can develop smaller, lighter, and more functional products.
The new technology also supports more sustainable manufacturing. Smaller components require less raw material, shorter cycle times, and lower energy consumption. Eliminating additional manufacturing and assembly steps further reduces waste and improves resource efficiency throughout the production process.
Although the 3 mm collapsing core is currently at the prototype stage, initial results demonstrate its strong potential to expand the capabilities of precision injection molding and open new application areas for highly miniaturized plastic components.
While conventional collapsing cores are typically available in diameters ranging from 8 to 240 mm, Leonhardt's 3 mm solution enables the demolding of internal undercuts of approximately 7% of the core diameter. This opens new possibilities for manufacturing miniature components with geometries that were previously difficult or impossible to produce in a single molding process.
The technology enables highly miniaturized plastic parts with integrated undercuts to be produced directly by injection molding. Secondary assembly and post-processing operations can be significantly reduced or eliminated, improving part quality, process reliability, and manufacturing efficiency while lowering production costs.
The innovation is particularly relevant for applications in medical technology, microfluidics, precision engineering, and microsystems technology. By integrating complex internal features directly into molded parts, manufacturers gain greater design freedom and can develop smaller, lighter, and more functional products.
The new technology also supports more sustainable manufacturing. Smaller components require less raw material, shorter cycle times, and lower energy consumption. Eliminating additional manufacturing and assembly steps further reduces waste and improves resource efficiency throughout the production process.
Although the 3 mm collapsing core is currently at the prototype stage, initial results demonstrate its strong potential to expand the capabilities of precision injection molding and open new application areas for highly miniaturized plastic components.
Leonhardt e.K.
Contact
Mr. Wolfgang Leonhardt