Work with recycled plastic and 3D-printed molds

Additive manufacturing has established itself in recent years as a tool for prototypes and small series. However, as soon as large quantities of small plastic parts with consistent dimensional accuracy are required, 3D printing reaches its economic limits. This is precisely where RobotFactory, a company founded in 2006 by Andrea Martini and based in Mirano, comes in. The manufacturer develops compact injection molding systems that are specifically designed to be used in combination with 3D-printed tools.

Why move from 3D printing to injection molding?

While 3D printing has revolutionized prototyping and low-volume production, it becomes less efficient when manufacturing large quantities of small parts with fine, consistent details. Printing each component individually is time-consuming, and production speed quickly becomes a limiting factor as volumes increase.

Injection molding offers a practical solution to this challenge. Once a mold is available, it allows thousands of identical parts to be produced rapidly, with excellent surface quality and repeatable precision. This makes it particularly suitable for small components where uniformity and efficiency are essential.

By combining the strengths of both technologies, manufacturers can achieve the best of both worlds. 3D printing is used to design and produce the molds quickly and cost-effectively, while injection molding takes over for the mass production phase. The result is a faster, more scalable process that maintains high detail quality while significantly reducing production time per part.

This hybrid approach bridges the gap between prototyping and industrial manufacturing, enabling a smoother transition from design to large-scale production.

The first approach was to develop a very simple system, easy to use and accessible to all laboratories where a simple desk was available to house the system with a simple and inexpensive small air compressor.

From Pneumatic to Oleodynamic

Robot Factory brings benchtop plastic injection molding to a new level, with automatic solutions designed for prototyping, research, and small-scale production.

In recent years, the world of 3D printing and digital manufacturing has witnessed a growing interest in hybrid systems, capable of combining the design freedom of rapid prototyping with the robustness of consolidated industrial processes. This is precisely where the range of benchtop injection molding systems developed by Robot Factory comes into play. The company first introduced a pneumatic model, followed by a new generation of oleodynamic machines.

The Starting Point – Pneumatic Injection Molding

The pneumatic system was the first step toward democratizing injection molding. Powered by compressed air, it can handle volumes up to 32 cm³ with an injection force generated by a Ø63 mm cylinder.

The operating principle is simple: plastic is heated in a chamber until it reaches melting point and then injected into a mold, generally made of two aluminum shells. Besides metals, molds can also be produced in resin or via 3D printing, provided they are resistant to high temperatures.

With its compact size (260×400×700 mm), light weight (14 kg), and limited power consumption (340 W), this solution has made one of the most widely used industrial processes accessible to a broader audience, traditionally tied to expensive systems designed only for large-scale production. This is one of the reasons why our system is now present in every country in the world, from Europe to Asia, from South Africa to New Zealand, from Canada to Australia, from the USA to Chile, from Saudi Arabia to India, in the most important global companies such as Department of National Defence of Canada, Arduino, Fraunhofer – IAP, Boeing Aerostructures, Miele, ecc.

The Evolution – Oleodynamic Injection Moldin

As a natural evolution of pneumatic 3D printing injection molding technology and in response to the growing demand for injecting materials in larger quantities and sizes, we have developed the new hydraulic 3D printing injection molding system.

Thanks to a hydraulic pump that guarantees up to 1,900 kg of extrusion force and a clamping force of up to 4 tons with a 100 cm³ injection chamber, the new systems respond to the growing need to produce larger objects with greater process control.
With this new offering, Robot Factory confirms its commitment to making industrial technologies accessible, bringing them closer to the world of 3D printing, design, and digital manufacturing.

A portal structure ensures stability and robustness, while the hydraulic pump delivers pressures up to 150 bar, equivalent to around 1,900 kg of extrusion force. With a benchtop vise capable of closing with up to 4 tons of force is also included.

Automatic versions work with a maximum temperature of 350 °C and support a wide range of raw materials, including recycled plastics—highlighting the focus on economical and environmentally friendly production.

Automatic version: equipped with time-based management and automatic material feeding, allowing repeatable cycles better suited for small production runs.

With technical specifications (1,250 W total power, approx. 64 kg weight, 900 mm height) and operator safety, with protective grills preventing accidental machine start-up.

Applications and Advantages

These systems were conceived as versatile tools for:
• rapid prototyping,
• research and development,
• small-scale production in fields such as electronics, jewelry, model making, and medical devices.

Key benefits include:
• lower costs compared to traditional industrial equipment,
• compatibility with widely available raw materials,
• the ability to use recycled plastics,
• compactness and ease of use, making them suitable even outside industrial environments.

Besides of course the main advantages: reduced costs, compatibility with recycled plastics, compact size, and attention to operator safety.

Robot Factory Benchtop Injection Molding system offers a breakthrough solution for industries producing small-scale parts, particularly in healthcare and precision manufacturing. This compact technology enables cost-effective, rapid production using plastic injection methods. For companies manufacturing medical devices or small, intricate components, the system facilitates faster prototyping and short production runs, making it ideal for producing high-quality, consistent results. Features like automated material feed and oleodynamic vices enhance efficiency, while supporting the use of recycled materials aligns with sustainability goals.

This benchtop system are perfect for health-related industries where precision, quality, and speed are critical. It provides an opportunity to reduce manufacturing costs while delivering highly detailed parts—ideal for medical tools, small prosthetics, or healthcare accessories. With the added flexibility of using 3D-printed or aluminum molds, businesses can scale production with minimal waste and high repeatability, driving innovation and expanding production capabilities.

Key Benefits for Healthcare and Small-Part Manufacturing:

• Cost-Efficiency: Reduces reliance on expensive industrial equipment, offering affordable production runs.
• Precision: Achieves high-resolution molds for small, intricate medical components or precision-engineered products.
• Automation: With automatic material feeding and time management, the system ensures smooth, repeatable production cycles.
• Sustainability: Compatible with recycled plastics, aligning with eco-friendly manufacturing practices.
• Flexibility: Supports a wide range of mold materials, including 3D-printed resins, offering design flexibility.

Robot Factory’s system is especially useful for businesses looking to innovate, offering faster time-to-market for new products while maintaining high production standards. For small-scale manufacturers in healthcare or specialized industries, the Benchtop Injection Molding system is a game-changer.

Application Areas

Medical Devices
From pneumatic systems to fully automatic hydraulic solutions, Robot Factory provides a reliable platform for the production of plastic components for low- to medium-volume medical applications.

The modular architecture supports process validation, functional testing, and pilot production, ensuring repeatability, controlled parameters, and consistent quality—key requirements for regulated environments.

Prototyping & R&D
Robot Factory injection molding systems bridge the gap between rapid prototyping and real production.

Compatibility with 3D-printed molds and precise process control allow engineers to test materials, geometries, and production cycles, significantly reducing development time and iteration costs.

Small & Medium Enterprises (SMEs)
Designed to meet the needs of SMEs, Robot Factory systems enable a gradual and flexible introduction of injection molding technologies.

The scalable, modular design allows production capacity to grow with demand, while maintaining industrial-grade quality, optimized investment, and fast time-to-market.

Education & Training
Ideal for educational and training environments, Robot Factory systems provide a hands-on approach to injection molding technologies.

An intuitive interface and modular structure help students and technicians understand the entire manufacturing process, from mold design to finished parts, supporting practical and applied learning.

Conclusion

From pneumatic solutions to fully automatic hydraulic systems, Robot Factory demonstrates how industrial injection molding technologies can be seamlessly integrated into the world of 3D printing and customized manufacturing.

Thanks to a modular and scalable architecture, these systems bridge the gap between laboratory development and industrial production, enabling designers, makers, and small to medium-sized enterprises to develop, test, and manufacture plastic components with optimized lead times and costs, while maintaining high standards of quality and process repeatability.

A wide range of application examples and system demonstrations is available on Robot Factory’s official YouTube channel, providing further insight into the capabilities and performance of their solutions.