How INSIZE Helped a Leading Injection Molding Machine Manufacturer Improve Inspection Efficiency

Background

As demand from industries such as new energy vehicles, consumer electronics, and precision medical devices continues to rise, injection molding machine manufacturers face mounting pressure to improve accuracy, consistency, and reliability across every stage of production.

A leading injection molding machine manufacturer with more than 20 years of industry experience produces high-performance equipment for the automotive, consumer electronics, medical device, and industrial sectors. As customer requirements for precision and reliability increased, the company sought to strengthen quality control throughout its production process.

To support its quality objectives, the manufacturer adopted a range of INSIZE measurement solutions across multiple production and inspection processes.

Challenges

The performance of an injection molding machine depends critically on the machining and assembly accuracy of its core components. This manufacturer faced measurement challenges at several key stages:

●  Machine tool guideway inspection: Straightness and parallelism of guideways directly affect overall machine accuracy and service life. Conventional measurement methods were too slow and insufficiently stable for complex workshop conditions.

● Tie rod GD&T inspection: Detecting runout and geometric tolerances on tie rods and other transmission components is essential for smooth machine operation. Traditional fixturing was cumbersome, making high-volume on-site inspection difficult and slowing production.

● Metal 3D printing accuracy: The company's in-house additive manufacturing line for customized high-end components required high-precision position feedback to ensure dimensional accuracy and batch consistency.

● Deep-hole internal inspection: Conventional methods could not reliably detect surface roughness, R-corner defects, or micro-cracks inside tie rod center holes and other hidden cavities — leaving potential quality risks undetected.

Solution

INSIZE provided a comprehensive measurement solution covering all four inspection scenarios, enabling full-process precision control from component machining through final assembly.

Guideway Inspection — Precision Levels

INSIZE precision levels and electronic levels , with micrometer-level accuracy, are used to inspect straightness, parallelism, and levelness of machine tool guideways throughout machining and assembly. Their strong anti-interference performance and portability allow reliable measurement in demanding workshop environments with minimal setup time.

Engineer using INSIZE electronic level on-site

Tie Rod Inspection — Magnetic Stands + Dial Indicators

INSIZE high-stability magnetic stands paired with IP54-rated waterproof dial indicators provide an efficient solution for inspecting tie rods and other shaft-type components. The strong magnetic base enables quick, secure mounting across a variety of surfaces. Circular runout, end-face runout, and other geometric tolerances can be measured directly on the production floor — improving inspection throughput and accuracy for high-volume batches.

Customer-installed INSIZE IP54 dial indicators and magnetic stands

Metal 3D Printing — Linear Encoders

INSIZE high-precision linear encoders provide full-stroke position feedback for the company's metal 3D printing equipment. With micrometer-level resolution and excellent anti-interference capability, they enable closed-loop control of motion axes during printing, ensuring dimensional accuracy and consistency for complex customized metal parts.

INSIZE linear encoders adopted by the customer

Internal Cavity Inspection — Industrial Videoscope

INSIZE industrial videoscopes address the challenge of non-destructive internal inspection in deep holes and hidden cavities. Without disassembly or damage to the workpiece, engineers can visually inspect the interior of tie rod center holes and other deep features — identifying surface roughness issues, R-corner machining quality, micro-cracks, and other defects with high-definition imaging.

Engineer conducting on-site inspection with INSIZE videoscope

The customer implemented INSIZE electronic levels, dial indicators, magnetic stands, linear encoders, and industrial videoscopes across its production workflow. These solutions were integrated into machining, assembly, additive manufacturing, and final inspection processes to improve measurement efficiency and maintain consistent quality standards.

Results

By integrating INSIZE measurement products across its production workflow, the manufacturer achieved precision control from component machining and machine assembly through final quality inspection.

● Inspection efficiency at key processes improved by approximately 30%

● Core component machining and assembly accuracy maintained at micrometer level

● First-pass yield rate improved through more consistent inspection and process control.

● Overall machine stability and service life substantially enhanced

These improvements have strengthened the manufacturer's position in global high-end markets, supporting the continued competitiveness of its injection molding machine product line.

Contact your local INSIZE representative or visit www.insize.com for more information about industrial measurement solutions.