M5 Micro
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Capability Spotlight · Fiber Optics & Photonics

High-Precision
Fiber-Optic
Micro Molded

M5 Micro Molding and Micro Machining capabilities are a direct fit for the tight concentricity, controlled end-face geometry, and sub-micron alignment demands of fiber-optic ferrules — for AI compute, supercomputers, robotics, and satellite interconnects.

Micron-aware geometry Automation-ready molding Hybrid ferrule / fiber / polymer parts PPAP-ready documentation
M5 Fiber-Optic Capabilities Presentation — Cover Slide
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Founded
2016
Hutchinson, Minnesota
Micro Machining
5-axis
KERN Micro Vario
Micro Molding
0.0001 g
Thermoplastics & MIM
Wire EDM
0.001 mm
Mitsubishi MV1200S
Industries Served
9+
Medical, photonics & more
Est. 2016 · Hutchinson, MN · Micro Molding & Machining

Precision measured
in microns.
Automation built in.

Micro injection molding capable of complex geometry, ultra-tight tolerances, and shot sizes from 0.0001 g — paired with 5-axis lights-out machining, wire EDM, and complete in-house metrology. Medical devices, fiber-optic ferrules, photonics, and microfluidics.

Micro machining & micro molding in the same facility — prototype to production
0.0005 g min shot size
·
24/7 lights-out machining
·
sub-µm repeatability
·
2016 founded
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Complex Geometry. Extreme Precision.

M5's micro injection molding handles what most shops turn away — ultra-small shot sizes, complex multi-feature geometry, and tolerances measured in microns. Thermoplastics and MIM, with overmolding and insert molding in the same run.

MOLDING M5iE Micro Molding System 0.0001–0.6 g shots Robotic Handling 6-axis arm Vision Inspection 100% in-line Secondary Machining in-cell ops Tray Loading & Packaging per-shot data TAP ANY STEP TO LEARN MORE
01 / MOLDING
M5iE Micro Molding System
Purpose-built for micro-scale work — shot sizes from 0.0001 g to 0.6 g. Runs thermoplastics and MIM (metal injection molding). Complex multi-feature geometry, thin walls, and gage-quality cavities machined in-house by M5's own 5-axis.
02 / HANDLING
Robotic Part Handling
Precision part extraction directly from the mold, zero human touch. Robotic handling transfers parts to inspection or packaging without interrupting cycle time — enabling consistent, unattended production runs.
03 / INSPECTION
100% In-Line Vision Inspection
Every part inspected every cycle — not sampled. Vision system checks critical dimensions, surface defects, and flash. Bad parts are automatically rejected. SPC data captured per shot. PPAP-ready traceability built in.
04 / SECONDARY OPS
Secondary Machining
Drilling, threading, trimming, or custom secondary operations can be integrated into the same production run — eliminating separate machine moves and reducing handling. Different tooling setups accepted per program.
05 / OUTPUT
Tray Loading & Packaging
Parts go directly from inspection to organized trays with per-slot traceability. Each tray position is mapped to shot data — material lot, press parameters, and vision result. PPAP-ready documentation included.

Full-Stack Micro Manufacturing

Hover each card to see specs. Everything under one roof in Hutchinson, MN.

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Micro Injection Molding
Thermoplastics & MIM — shot sizes from 0.0001 g
↔ hover for specs
Micro Injection Molding
  • Shot range: 0.0001 g – 0.6 g
  • Thermoplastics + MIM (Metal Injection Molding)
  • Overmolding, insert molding, dual-shot (2K)
  • Gage-quality molds machined in-house
  • Medical-grade materials available
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🔩
5-Axis Micro Machining
KERN Micro Vario · 24/7 robotic cell
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5-Axis Micro Machining
  • KERN Micro Vario + HEIDENHAIN TNC 640
  • Sub-micron repeatability
  • End mills down to 0.0101 mm dia.
  • 24/7 lights-out via robotic tending cell
  • Mold work, photonics fixturing, tooling
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Wire EDM
Complex profiles in hardened tool steel
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Wire EDM
  • Complex profiles & fine-feature geometries
  • Hardened tool steel — no annealing needed
  • Features that can't be milled
  • Micro-scale wire diameters
  • Tight angular and contour tolerances
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🔬
Small-Hole EDM
Vents, gates, microfluidic pathways
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Small-Hole EDM
  • Ultra-small diameter hole burning
  • Micro-fine electrode technology
  • Mold vents, gates, ejector pin bores
  • Microfluidic channel pathways
  • Hardened steels — no pre-heat
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📐
Full Metrology
CMM · Vision · Optical Comparator
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Metrology & Inspection
  • Mitutoyo CMM
  • Mitutoyo Vision System
  • Starrett Optical Comparator
  • Gage pins & surface profilometry
  • FAIR / ISIR / PPAP-ready docs & CpK
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Precision Toolmaking
Gage-quality molds, fixtures & production tooling
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Precision Toolmaking
  • Gage-quality mold cavities & cores
  • Production molds built in-house on KERN 5-axis
  • Fixtures, gauges & inspection tooling
  • Tool steel hardening in-house — no outsourcing
  • Mold modifications & repairs
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Surface Grinding & Heat Treat
Low-micron finishes · in-house hardening
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Grinding & Heat Treat
  • Flatness & parallelism in the low-micron range
  • Mold bases & precision blocks
  • In-house heat treat — tool steels & alloys
  • No outsourcing = faster turnaround
  • Tight hardness tolerance control
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Overmolding & Insert Molding
Multi-material · pin & leadframe inserts
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Overmolding & Insert Molding
  • Multi-material overmolds
  • Pin & leadframe insert molding
  • Two-material single-cycle (2K)
  • All run in the same integrated cell
  • Medical & photonics assemblies
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How Small Is "Micro"?

Drag the slider to explore M5's shot size range. Each stop shows a real part or reference at that scale.

Shot size: 0.0005 g — smallest shot to date
M5's smallest shot to date: 0.0005 g — roughly the weight of a single grain of fine salt. That's the plastic in each part.

Our KERN five-axis machining centers with internal pallet loading run inside fully enclosed robotic cells. They don't stop. Not at night, not on weekends.

cumulative lights-out hours

Every hour counted above is an hour no human had to stand at the machine. Capacity that ships on time, even when no one's in the building.

Industries We Serve

Select your industry to see how M5's capabilities map to your specific needs.

Medical Devices

M5's core market. Surgical tools, catheters, implant components, and diagnostic parts require tight tolerances, material traceability, and documentation that M5's integrated cell delivers every cycle.

Micro injection molding — biocompatible materials
FAIR / ISIR / PPAP documentation
100% in-line vision inspection
CMM & dimensional verification
Overmolding & insert molding assemblies
Example Part Types
Surgical instrument tips & housings
Catheter components & connectors
Implantable device prototypes
Diagnostic cartridge components
Pacemaker-class micro parts
Fiber-Optic Ferrules

Ferrule geometry demands tight concentricity, controlled end-face geometry, and bore diameters held to fractions of a micron. M5's 5-axis and molding capabilities were built for exactly this.

5-axis micro machining — bore geometry
Sub-micron concentricity control
Small-hole EDM for precision bores
Vision system — end-face geometry check
Example Part Types
SC, LC, MTP/MPO ferrule bodies
Multi-fiber alignment sleeves
Precision bore inserts
Connector housings
Photonics

Lens mounts, optical housings, and sub-micron alignment fixtures require a machinist who thinks in microns by default. M5's KERN cell and full metrology department are purpose-fit.

Sub-micron positioning accuracy
Optical fixturing & alignment components
5-axis complex geometry
Surface finish profilometry verification
Example Part Types
Lens mounts & housings
Optical alignment fixtures
Beam-splitter mounts
Photonic chip packaging components
Microfluidics & Diagnostics

Disposable cartridges and diagnostic chips demand micro-scale channel geometry, clean materials, and high-volume repeatability.

Micro-channel mold tooling
Small-hole EDM for microfluidic pathways
High-volume molding cell
Per-shot traceability
Example Part Types
Diagnostic disposable cartridges
Optical window inserts
Micro-channel chip bodies
Drug Delivery

Drug delivery devices demand micron-level orifice geometry, material purity, and documented traceability.

Precision nozzle & orifice tooling
Small-hole EDM for delivery ports
PPAP-ready documentation
Medical-grade material processing
Example Part Types
Inhaler nozzle bodies
Auto-injector components
Micro-dosing valve parts
Aerospace & Defense

Tight-tolerance small parts, exotic materials, and traceability documentation align squarely with M5's capabilities.

5-axis complex micro geometry
Exotic alloys & hardened steels
CMM dimensional verification
First article inspection
Example Part Types
Guidance sensor housings
Optical sensor mounts
Precision fixtures & tooling
Electronics & Connectors

Miniaturized connectors and housings require the same micro-scale precision as medical work. M5's insert molding handles metal-in-plastic assemblies with ease.

Insert molding — pins & leadframes
2K / dual-shot capability
100% vision inspection
High-volume cell production
Example Part Types
Micro-connector bodies
Leadframe overmolds
Sensor housings

Equipment & Specs

Click any card to see detailed specifications. All operated by M5 staff in Hutchinson, MN — no outsourcing.

5-Axis Machining
KERN Micro Vario
HEIDENHAIN TNC 640 Control
ControlHEIDENHAIN TNC 640
Positioning accuracyMicron-level
RepeatabilitySub-micron
Min. tool diameter0.0101 mm
Operation24/7 lights-out
TendingEnclosed robotic cell
Metrology
Mitutoyo CMM
Coordinate Measuring Machine
Type3D coordinate
GD&TFull interpretation
DocumentationFAIR / ISIR / PPAP
StatisticsCpK studies
Metrology
Mitutoyo Vision System
Non-contact optical measurement
TypeNon-contact optical
Use caseMicro features & profiles
Metrology
Starrett Optical Comparator
Profile projection measurement
TypeOptical profile projection
ApplicationCross-section profiles
EDM
Wire EDM
Wire electrical discharge machining
MaterialsAll electrically conductive
FeaturesSub-micron accuracy
EDM
Small-Hole EDM
Hole burning / sinker EDM
ElectrodeMicro-fine
ApplicationsVents, gates, bores, channels
MaterialsAll electrically conductive

What Process Do You Need?

Tell us about your part and we'll point you to the right M5 capability.

⚙️
Select your part parameters and we'll recommend the right M5 process.

Want a formal DFM review? Submit an RFQ →

Press Coverage

Built by Toolmakers

M5 Micro started as a specialty micro tooling shop — born from the vision of an owner who saw where the industry was heading. Everything was getting smaller. Work too small and too precise for most shops to touch.

Founder Jon Baklund and lead toolmaker and designer Alex Madsen launched M5 — Minnesota Micro Molding, Machining & Manufacturing. Together, they built the processes, programmed the machines, and designed everything they needed — including the patented M5 iE Micro Molding System, a proprietary approach to micro injection molding developed entirely in-house.

M5 has palletized and automated across the shop to maintain the workloads and accuracies required for the micro machined and molded parts and assemblies they've been perfecting together for years.

Talk to Jon →LinkedIn
2016
M5 Founded
Jon Baklund establishes Minnesota Micro Molding, Machining & MFG in Hutchinson, MN.
2017–2018
Micro Niche Established
Customer mix shifts toward medical device makers. Investment in micro-scale molding and machining capabilities begins.
2019–2020
2 KERN Micro Vario's Installed
Sub-micron repeatability with internal robotic pallet loading.
2020–Present
Full-Stack Micro Manufacturing
Micro injection molding, in-house toolmaking, 5-axis lights-out machining, EDM, and a full metrology department — operating as a complete micro-manufacturing resource under one roof.
M5 Micro — Fiber-Optic Capabilities
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Frequently Asked Questions

What is the smallest shot size M5 Micro can produce?
M5's smallest shot to date is 0.0001 g — smaller than a grain of fine salt. Standard production runs from 0.0001 g up to 0.6 g per shot.
What materials does M5 work with?
Engineering thermoplastics including PEEK, plus metal injection molding (MIM) materials including cobalt chrome and stainless steel. The 5-axis also machines hardened tool steels and exotic alloys.
What industries does M5 serve?
Medical devices, microfluidics, fiber-optic ferrules, photonics, and defense. If a component requires tolerances in the micron range, M5 is built for it.
What machine runs the 5-axis machining?
Two KERN Micro Vario machines with sub-micron repeatability, internal robotic pallet loading, and 24/7 lights-out capability. Both active since 2020.
Does M5 offer lights-out manufacturing?
Yes. The KERN 5-axis and Wire EDM run 17,520 hours per year combined — nights, weekends, holidays — without operator intervention. Every cycle is tracked and logged.
Can M5 produce microfluidic components?
Yes. Micro molded channels, small-hole EDM bores, and wire EDM profiles are all in-house. M5 can produce complete microfluidic device components from a single source.
What is metal injection molding (MIM)?
MIM combines injection molding with powder metallurgy to produce complex metal parts at micro scale. M5 runs MIM on the same press platform as thermoplastic molding, with post-sinter 5-axis machining available.
Where is M5 Micro located?
Hutchinson, Minnesota. Founded in 2016. Micro molding and 5-axis machining under one roof — no outsourcing, no hand-offs.

Request a Quote or DFM Review

NDA available. Typically respond within one business day.

Phone
(952) 261-9804
Mon–Fri, 7am–5pm CT
Email
jon@m5-micro.com
Typically reply within 24 hours
Address
13835 200th St
Hutchinson, MN 55350, USA
Service Area
United States & Canada
NDA available on request
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