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Home / How to Choose an Injection Molding Robot for High-Precision Products: HDW’s High-Speed ​​Response

How to Choose an Injection Molding Robot for High-Precision Products: HDW’s High-Speed ​​Response

2025/11/19 By le zhan

High-Precision Plastic Products(1)

Suppose an injection molding robot cannot maintain stable positioning, resulting in microscratches on parts and non-standard dimensions. In that case, it not only wastes significant production time and costs but also compromises part quality. Therefore, for high-precision applications and scenarios with stringent appearance requirements, specialized injection molding robots are necessary. Topstar’s HDW series, designed specifically for use with 75-1300 ton horizontal injection molding machines, offers high-speed response and precise positioning, and features three-axis motion, AC servo drives, and rigid guideways. These characteristics effectively handle the production of injection-molded products with strict tolerances and extremely high surface finish requirements.

Why do high-precision products require specialized injection molding robot?

High-precision products, such as microelectronic connectors (tolerance ±0.005 mm), medical implants, or aerospace fasteners, push injection molding technology to its limits. Unlike standard parts, high-precision injection molding robots need to meet three requirements:

Micron-level precision: Even tiny positioning errors (above 0.01 mm) can ruin a part. The robot must be precisely aligned with the mold in each cycle to avoid dimensional deviations or surface damage.

Stable movement: Vibration or jitter can be transmitted to the mold or part, causing defects or warping. The robot’s movement must be smooth and consistent.

Speed ​​and precision in balance: High-precision injection molding typically uses fast cycles (5-10 seconds). The robot must quickly remove parts to avoid cooling deformation without compromising precision.

Perfect control: Precision parts cannot withstand rough gripping or misalignment—the robot needs gentle, controllable movement.

General-purpose injection molding robots cannot meet these requirements: they are designed for mass production, not high-precision manufacturing. In contrast, the HDW series prioritizes precision from the outset. “The key to high-precision injection molding lies in eliminating variables,” explains the head of R&D at Toptsar Robotics. “HDW eliminates this variable—its performance is predictable, repeatable, and precise.”

Why do high-precision products require specialized injection molding robot?

HDW Series Injection Molding Robot, Compatible with 75-1300 Ton Horizontal Injection Molding Machines

The first step in choosing an injection molding robot for high-precision injection molding operations is ensuring it is compatible with your injection molding machine. The HDW series integrates seamlessly with horizontal injection molding machines ranging from 75 to 1300 tons:

75-200 Ton Class: Ideal for manufacturing micro-precision parts (e.g., electronic pins with a diameter of 0.5 mm). HDW’s compact design allows it to fit into production lines with limited space, while its precision matches the machine’s micro-molding capabilities.

200-500 Ton Class: For processing medium-sized, high-precision parts. HDW’s extended reach can handle multi-cavity molds without compromising alignment accuracy.

500-1300 Ton Class: Suitable for large, precision parts. The robust construction of HDW machines matches their powerful machining capabilities, enabling efficient processing of heavy, high-precision parts.

This broad compatibility means manufacturers can improve precision without replacing existing injection molding machines. HDW also excels at dual tasks: it can remove finished high-precision parts and mold gates in a single cycle, eliminating the need for secondary finishing and reducing handling-related defects by 40%.

75-1300 Ton Horizontal Injection Molding Machine

Single-stage and telescopic versions – achieving flexibility for precise setup

High-precision production lines vary in terms of space, mold design, and part dimensions. Therefore, the HDW series offers two versions to accommodate various situations, both optimized for vertical movement to complement high-precision molding:

Single-stage version: Standard 900 mm vertical travel (expandable to 1100 mm). Ideal for production lines with ample vertical space, providing direct, rapid access to the mold.

Telescopic version: Offers 900 mm or 1100 mm vertical travel, with a telescopic arm that extends horizontally to reach deep molds or confined spaces. This is crucial for high-precision parts in multi-cavity molds.

Both versions maintain HDW’s consistent precision and speed; the only difference lies in the entry and exit methods. Topstar’s application engineers will help you choose the version best suited to your equipment, measuring mold depth, machine clearance, and part dimensions to recommend a single-stage or telescopic entry and exit method, ensuring the robot works seamlessly with your process flow.

Three-Axis Motion and AC Servo Drives—Speed ​​and Precision Combined

High-precision molding requires speed to avoid cooling defects, but speed cannot come at the expense of precision. The HDW series achieves a balance between these two thanks to its three-axis motion system and high-performance AC servo motors:

Three-Axis Motion: The robot can move along the lateral, longitudinal, and spindle axes, covering all the movements required to enter the mold and remove the part. This coordinated motion eliminates redundant steps, reducing part removal time to 0.8 to 1.5 seconds, which is sufficient for a 5-second molding cycle without compromising alignment accuracy.

AC Servo Motors: These motors provide instant, precise torque control, enabling the HDW to accelerate smoothly and stop within ±0.005mm of the target position. Unlike hydraulic robots or stepper motors, AC servo motors ensure precise control of every movement—crucial for machining high-precision parts.

In Topstar’s lab tests, the HDW series robots achieved a repeatability of ±0.01 mm, far exceeding the general robot industry average of ±0.05 mm. This three-axis design also enables gentle operation: the injection molding robot decelerates as it grips a part. It accelerates once it leaves the mold, preventing damage to delicate, high-precision components.

injection molding robot

High-rigidity guideways and open servo positioning achieve higher precision.

While speed and compatibility are critical, true high precision relies on two core features of the HDW: high-rigidity guideways and an open servo positioning control system. Together, these eliminate vibration and ensure consistent accuracy.

Through high-rigidity guideways, the HDW’s robotic arm runs on precision-machined, reinforced rails, effectively resisting bending and vibration. Even at full speed, the robot’s movement is remarkably stable—no wobbling, no deviation. This is crucial for surface-sensitive parts, as even the slightest scratch is unacceptable. The open servo positioning control system dynamically adjusts the robot’s position using real-time feedback from mold sensors. It compensates for minor mold wear, temperature changes, or machine vibrations, maintaining a positioning accuracy of ±0.008mm. This level of adaptability is crucial for parts with extremely high tolerance requirements. Topstar’s field data confirms this: factories equipped with HDW equipment report a 65% reduction in precision-related defects compared to factories using conventional injection molding robots.

Delivering stable, high-precision product output

High-precision products require injection molding robots that can not only remove parts but also maintain their integrity. The HDW series perfectly achieves this goal with its broad compatibility (suitable for 75-1300 ton  injection molding machines), flexible dual-version design, three-axis AC servo drive motion, and ultra-high-precision positioning system. It eliminates the possibility of the robot itself being a source of defects, transforming unstable production into reliable, high-quality output.

 

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