Scalable Production

From single-digit functional prototypes through small-series validation builds and into full regulated volume production at several millions of parts per year — all on the same Danish site with the same engineering team. Carmo runs more than 30 modern injection moulding machines with clamping forces from 25 to 250 tonnes, supported by in-house prototyping, automation and robotics, and validated ISO Class 8 cleanroom assembly for medical applications.

Two routes converge. Carmo Print Moulding handles development-phase and bridge-production volumes in production material without committing to definitive steel tooling — economic where lifetime volumes don't justify a full tool. For larger small-series runs and ongoing production, definitive tooling and standard injection moulding handle the work efficiently across the 25-to-250-tonne machine range. The integrated design and tooling teams help you choose the right route during scoping.

Your project doesn't change hands at the scale-up boundary. The transition from small-series to full volume happens on the same site with the same engineering team. Carmo Print Moulding tooling for prototype and bridge volumes transitions to definitive injection-moulding tools designed by the same team; once your project enters validation builds and volume production, the certified ISO 13485 QMS engages and continues through regulated volume. Your supplier qualification, audit trail, and documentation extend rather than restart at the validation-build boundary.

Ramp speed depends on tooling status and material lead times rather than on team availability. For projects already through Carmo Print Moulding development, definitive tooling can be designed and built in parallel with final validation builds — so ramp is sequenced around your regulatory or commercial date rather than around supplier capacity. Specific timelines settled during scoping.

Yes. The machine fleet (more than 30 modern injection moulding machines, 25 to 250 tonne range) plus in-house prototyping, automation, and cleanroom assembly carry meaningful headroom for new project intake. Capacity planning is part of the scoping discussion — you get a clear view of available slots before committing.

Flexibility comes from the integrated setup. If you have multiple projects at different lifecycle stages — one in development on Carmo Print Moulding, one in volume production, one in redesign — you deal with the same engineering team and the same site for all of them, and the same certified QMS governs each project from validation builds onward. The cost of moving a project between Carmo Print Moulding and definitive tooling (or back, for late-stage variants) is meaningfully lower than the equivalent supplier-switch cost would be.

Automation cells are designed around your components rather than as generic line equipment, so they can be reconfigured when the component changes. Most injection moulding cells are equipped with highly versatile 6-axis robots, and in-house design of advanced grippers secures high flexibility and responsiveness when variants or new launches need to come online quickly. Robotics in cleanroom assembly supports process repeatability without locking the line to a single product — automation-grade throughput on stable products, fast reconfiguration on variants and new launches, all under one engineering function.

Both. Downstream assembly, inspection, printing, and packaging happen in validated ISO Class 8 cleanrooms at the same site as moulding, all under the certified ISO 13485 QMS. A component can move from raw material through final packaged form without leaving Carmo's site or quality system — useful both for medical regulatory documentation and for shortening your logistics chain.