Tiny Titans: Micro Parts Make a Big Impact

Small components with a big impact—this best describes the innovative micro parts from Freudenberg Sealing Technologies. The main areas of application for these tiny components with external dimensions up to ~20 mm are fluid handling valves, pumps, mixers and small electric motors, such as those used in medical technology. Wherever hygiene, safety and precision play a decisive role—from anesthesia machines to dental drills—micro parts make an indispensable contribution to safe and efficient use.

Material Challenges in Micro Part Manufacturing

Micro part manufacturing is a highly specialized field that requires careful consideration of precision, materials, tooling, cost and scalability. Advancements in technology, such as improved tools and techniques, are continuously helping to overcome some of these challenges and enable manufacturers to meet market requirements.

The selection of materials for micro part manufacturing is a critical aspect that directly influences the performance and reliability of the final product. Specialized materials such as FKM (fluorelastomer), FFKM (perfluoroelastomer) and EPDM (ethylene propylene elastomer) are tailored to meet the demands of various industries, including the medical technology, food & beverage and automotive sectors.

FKM, which is characterized by good chemical resistance and temperture resistance up to 200°C, is ideal for environments with aggressive media. FFKM offers very high chemical resistance and reliably withstands temperatures of up to 230 °C, making it ideal for high-demand environments where durability is essential. EPDM on the other hand, is particularly resistant to ozone, UV radiation and hot water, making it best suited for environments with moisture and steam elements.

This wide variety of materials makes it possible to develop customized sealing elements for different applications, whether in medical technology, food and beverage industry or the automotive sector, where maximum precision or hygiene are crucial. The high durability and reliability of micro parts make a decisive contribution to ensuring the safe operation of devices even under extreme conditions. While challenges in micro part manufacturing exist, the potential for these parts to make an impact is immense.

Making an Impact: Ventilators in the Medical Industry

Micro components, typically measuring less than 20 mm, are essential in preventing leaks and ensuring the smooth operation of critical applications, particularly in medical devices where miniaturization is a key trend. As components continue to shrink, the demand for smaller valves and valve components intensifies. In this evolving landscape, precision is paramount to maintain functionality and reliability in these miniature systems.

The valve anchor, for example, controls the flow of anesthetic gases in anesthesia machines to enable the precise dosing, which is essential for patient safety. Made from a combination of metal and FFKM, the valve anchor can withstand even the most aggressive anesthetic gases, which is crucial for the long-term safety and function of the devices.

As components continue to shrink, the demand for smaller valves and valve components intensifies. With a total height of less than 9 mm, the valve anchor controls the flow of anesthetic gases in anesthesia machines to enable the precise dosing, which is essential for patient safety.

Another device in the operating theater that micro parts support is the ventilator. In this application, a miniature flipper valve seal enables the precise control of the required volume of respiratory gases. The seal made of FKM or EPDM impresses with its high media resistance. The high-quality material combination ensures a long service life even under extreme conditions and ensures millions of switching cycles without any loss of performance.

Making an Impact: Drills in Dentistry

In addition to applications relating to surgical procedures, micro parts play a key role in dentistry, such as the brake and sealing disk, which was specially developed for use in dental drills. The combination of sealing and braking function stops the dental drill in a fraction of a second after treatment is completed. This immediate stop noticeably increases patient safety and the comfort of dental treatment.

Made from durable and sterilization-resistant elastomers, the less than 0.2 mm thick brake and sealing disc can withstand extreme loads at high speeds without losing its function or sealing performance. In addition, the brake and sealing disk prevents media from flowing back into the handpiece and thus contributes significantly to the hygiene of the treatment.

Micro parts play a key role in dentistry, such as the brake and sealing disk, which was specially developed for use in dental drills.

Another application in this area is the hygienic preparation of drinking water for the dental treatment unit. An elastomer composite part named after its shape, the so-called “dog bone,” controls the even supply of water.

Micro parts in dentistry: an elastomer composite part named after its shape, the so-called 'dog bone,' controls the even supply of water. — Micro parts in dentistry: an elastomer composite part named after its shape, the so-called "dog bone," controls the even supply of water.

Making an Impact: Laboratory Analysis Equipment

The requirements for precision and reliability are particularly high in laboratory analysis equipment, such as HPLC (high performance liquid chromatography) systems and pipetting robots, making this an ideal application for micro parts. In these functions, hammer seals and rocker valves ensure precise control of the liquid dosage and prevent leaks that could lead to falsified analysis results. The rocker valve ensures precise control of the liquid dosage during the automatic pipetting process, while valve seat seals in HPLC devices prevent leaks and thus ensure reliable results.

The requirements for precision and reliability are particularly high in laboratory analysis equipment, such as HPLC systems and pipetting robots, making this an ideal application for micro parts.

In addition to their use in pumps and valves, micro parts are also used in small electric motors to seal rotating parts and ensure the performance of the motors. The precision and robustness of the materials used ensures that the seals retain their function even at high speeds and under extreme loads.

Making an Impact: Future Considerations

The future of micro parts is exciting and holds great potential in a variety of industries. These tiny components are essential in advancing technology, improving product performance, and enabling new applications across sectors. The focus is on new areas of application, improving production technologies and researching new materials that guarantee even greater durability and reliability in use. Trends driven by environmental considerations and technological advancements are especially topical.

PFAS and micro parts: The family of per- and polyfluoroalkyl substances (PFAS) is facing intense scrutiny. Starting in May 2025, U.S. companies that have manufactured PFAS in the U.S. or imported PFAS, or semi-finished or finished products containing PFAS between 2011 and 2022, will be subject to a reporting rule. Individual states are also starting to restrict the use of PFAS or require reporting. The scope and schedules vary significantly from state to state.

The materials in question for seals, such as PTFE and FKM, are high-performance materials: they have a long lifetime and a high temperature resistance; they are resistant to reactive media and resistant to wear. Freudenberg Sealing Technologies is currently evaluating whether there are alternatives to these materials in its products.

However, Freudenberg Sealing Technologies expects that there will be very few cases, if at all, where a 1:1 substitute is currently available that meets performance, service life, and other requirements for use in products. A substantial portion of the company’s compound portfolio is already based on FKMs produced without the use of fluorinated surfactants or manufacturing aids. The remaining portion of compounds will adopt the new technologies.

Hydrogen-emergent applications. Another notable example of how micro components are driving technological innovation can be found in hydrogen-emergent applications, particularly in the hydrogen production process through electrolysis. In this context, Freudenberg Sealing Technologies plays a pivotal role by providing advanced sealing solutions for electrolysis stacks. These stacks utilize electricity to split water into hydrogen and oxygen—a process that takes place within a specialized unit called an electrolyzer.

The demand for precise and reliable seals in these systems has spurred the development of a broad range of sealing solutions, including O-rings, gaskets, and integrated 2K-component sealing products. Freudenberg Sealing Technologies’ ability to customize the design and material properties of these seals for the harsh and dynamic conditions of electrolysis applications has been crucial. The main objective is to effectively contain electrolytic liquid, hydrogen, and oxygen, ensuring that each element stays within its designated place throughout the process.

This article was submitted by Dominik Linder, specialist, design engineering, Freudenberg Sealing Technologies and Tobias Gutsch, product manager, Freudenberg Sealing Technologies.

Machine Design accepts editorial submissions on how to solve specific design, engineering and technical problems. Submit your article query to [email protected].