Key takeaways A polymer is a material composed of very large molecules known as macromolecules. These molecules are formed from smaller molecules called monomers, but a monomer and a repeating unit are not always chemically identical. Polymer structure influences properties such as strength, flexibility, transparency, chemical resistance and heat performance. Selecting the right polymer is essential for successful plastic injection moulding and long-term product performance. Material selection increasingly includes recyclability, restricted substances, traceability and other sustainability requirements. What is a polymer? The question matters far beyond chemistry lessons. For product designers and manufacturers, polymer selection can determine whether a component is strong enough, dimensionally stable, chemically resistant, manufacturable and compliant with the requirements of its intended market. This guide explains what polymers are, how they are made, how their molecular structure affects performance and how manufacturers select polymers for plastic components. What Is a Polymer? The term polymer is commonly used to describe a large molecule made from repeating units. More precisely, the International Union of Pure and Applied Chemistry defines a polymer as a substance composed of macromolecules. A macromolecule is an individual molecule with a high molecular mass whose structure contains many units derived from smaller molecules. These smaller starting molecules are known as monomers. A useful distinction is therefore: Monomer: a molecule capable of taking part in polymerization; Macromolecule: an individual large polymer molecule; Polymer: a substance composed of many macromolecules; Polymeric material: the usable bulk material, normally including polymer molecules and potentially additives, fillers, pigments or reinforcements. This distinction matters because the performance of a plastic material is not controlled only by its basic polymer chemistry. Molecular weight, chain arrangement, crystallinity, additives and manufacturing conditions can all affect how the final material behaves. Natural and Synthetic Polymers Natural and synthetic polymers are based on the same general principle: smaller molecular building blocks form much larger molecular structures. Their origin and applications, however, are different. Natural polymers Synthetic polymers Cellulose Polyethylene Starch Polypropylene Proteins Polystyrene DNA PET Natural rubber Nylon Natural polymers are produced by living organisms. Cellulose provides structural support in plants, proteins carry out biological functions and DNA stores genetic information. Synthetic polymers are manufactured through controlled chemical processes. Their molecular structure and formulation can be adjusted for applications including packaging, electronic products, medical devices, construction components and industrial equipment. There are also materials that do not fit neatly into a simple natural-versus-synthetic division. Celluloid and rayon, for example, are produced by chemically modifying naturally sourced polymers. Vulcanized natural rubber is also a chemically modified natural material. PLA is typically manufactured industrially from biologically sourced feedstocks and is therefore commonly described as a bio-based polymer. Bio-based does not automatically mean biodegradable, and biodegradable does not automatically mean suitable for every recycling or composting system. These characteristics must be evaluated separately. How Are Polymers Made? Polymers are produced through polymerization: a process in which monomers or mixtures of monomers are converted into polymers. Polymerization mechanisms are often grouped into two broad categories: chain-growth polymerization; step-growth polymerization. These categories describe how molecular growth occurs. They should not be treated as exact synonyms for “addition” and “condensation” in every case. Chain-Growth Polymerization In chain-growth polymerization, polymer growth occurs at an active or reactive site on a growing chain. The process normally includes: initiation; propagation; possible chain transfer; possible termination. Many familiar polymers, including polyethylene and polypropylene, are produced through chain-growth reactions involving carbon-carbon double bonds. However, not every chain-growth polymerization works by opening a double bond. Ring-opening and other chain-growth mechanisms also exist. Step-Growth Polymerization In step-growth polymerization, molecules containing reactive functional groups combine with one another in successive steps. Monomers can react with other monomers, short chains or longer polymer chains. High molecular weight is normally achieved only after a large proportion of the reactive groups have reacted. PET and many polyamides and polyurethanes are produced through forms of step-growth polymerization. Some step-growth reactions are polycondensations and release a low-molecular-weight by-product. Other step-growth reactions proceed without releasing such a molecule. It is therefore more accurate to distinguish the growth mechanism from the precise chemical reaction involved. What Determines Polymer Properties? Polymer performance is influenced by several interacting factors rather than one single structural feature. Important factors include: chemical composition; molecular weight; chain length; chain branching; cross-link density; copolymer composition; orientation; crystallinity; intermolecular forces; additives and reinforcements; processing history. Changing one of these factors can significantly alter the performance of the final material. For example, both HDPE and LDPE are forms of polyethylene. HDPE has a more linear molecular structure that allows chains to pack together more closely. This contributes to higher density and stiffness. LDPE contains more branching, which prevents the chains from packing as efficiently. The resulting material is generally softer and more flexible. Homopolymers and Copolymers A homopolymer is produced from one type of monomer. A copolymer contains units derived from more than one monomer type. Depending on how those units are arranged, a copolymer may be: random; alternating; block; graft. Copolymers allow material developers to combine or balance properties that may not be available from a single homopolymer. For example, copolymerization may be used to adjust impact strength, flexibility, chemical resistance, clarity or processing behaviour. Amorphous and Semicrystalline Polymers Polymeric materials can also be described according to the way their molecular chains are arranged in the solid state. Amorphous polymers Amorphous polymers do not have extensive long-range crystalline order. They typically soften gradually as they pass through their glass-transition temperature. They do not generally have one distinct crystalline melting point. Common amorphous thermoplastics include: ABS; polycarbonate; polystyrene; PMMA. Many amorphous plastics can provide good dimensional stability, surface appearance and transparency, depending on the material. Semicrystalline polymers Semicrystalline polymers contain both ordered crystalline regions and less ordered amorphous regions. They normally exhibit both a glass transition in the amorphous fraction and a melting range associated with the crystalline regions. Common semicrystalline thermoplastics include: polyethylene; polypropylene; polyamide; POM; PEEK; PET. Semicrystalline materials often provide good chemical resistance, fatigue resistance and wear performance, but they can exhibit greater moulding shrinkage than many amorphous materials. Types of Polymers by Thermal Behaviour One of the most practical ways to classify polymeric materials in manufacturing is by how they react to heat. Thermoplastics Thermoplastics soften when sufficiently heated and harden again when cooled. This behaviour allows them to be processed through methods such as: injection moulding; extrusion; blow moulding; thermoforming. Thermoplastics can often be remelted and reshaped. However, this does not mean they can be processed indefinitely without losing quality. Repeated heating can cause thermal degradation, contamination and changes in molecular weight or performance. Polymer Typical applications LDPE Films, bags and squeeze bottles HDPE Pipes, crates and rigid containers PP Caps, living hinges and housings PS Trays, disposable products and packaging PET Bottles, fibres and formed containers ABS Housings and technical components PC Transparent and impact-resistant components PEEK High-performance technical components Thermosetting Polymers Thermosetting materials undergo an irreversible curing reaction that produces an infusible polymer network. Once fully cured, a conventional thermoset cannot simply be melted and reshaped in the same way as a thermoplastic. Excessive heating normally causes degradation rather than normal melting. Common examples include: epoxy resins; phenolic resins; melamine-formaldehyde; unsaturated polyester resins. Thermosets are used where characteristics such as heat resistance, chemical resistance, electrical insulation and dimensional stability are required. Elastomers An elastomer is a polymer that exhibits rubber-like elasticity. Conventional rubber elastomers normally use chemical cross-links to prevent polymer chains from permanently sliding past one another. This allows the material to deform and then recover its shape. Examples include: natural rubber; SBR; EPDM; silicone rubber. Thermoplastic elastomers are different. Their elastic behaviour is created by reversible physical structures rather than permanent conventional cross-linking, allowing them to be processed more like thermoplastics. Liquid silicone rubber, or LSR, is commonly processed through specialised injection moulding equipment. It is an elastomeric thermosetting material, not a conventional thermoplastic. The Role of Additives Commercial plastic grades normally contain more than the base polymer. Formulations may include: pigments; plasticizers; flame retardants; UV stabilizers; antioxidants; impact modifiers; glass fibres; mineral fillers; processing aids. These ingredients can improve or modify the performance of the material. However, additives can also affect recyclability, regulatory compliance, processing behaviour and the properties of recycled material. It is therefore more precise to evaluate a complete material grade than to assess only the name of the polymer family. Two polypropylene grades, for example, may behave very differently if one is unfilled and the other contains glass fibre, flame retardants or impact modifiers. Polymers in Plastic Manufacturing Polymer selection directly affects product design, tooling and production. Manufacturers normally evaluate: Application requirements mechanical load; impact exposure; operating temperature; dimensional tolerances; chemical exposure; UV exposure; electrical requirements; expected product lifetime. Processing requirements injection moulding; extrusion; blow moulding; compression moulding; overmoulding; insert moulding; liquid silicone rubber moulding. Appearance requirements colour; gloss; texture; transparency; visible flow lines; surface durability. Regulatory and customer requirements food-contact requirements; electrical and electronic equipment restrictions; flammability requirements; medical-device requirements; customer-specific material declarations; restricted-substance requirements. End-of-life requirements recyclability; material identification; recycled content; separability; waste reduction; repair and disassembly. The right polymer is therefore not simply the strongest or least expensive option. It is the material that provides the required performance while remaining suitable for m Manufacturing, compliance and the intended production volume. Common Polymers Used in Injection Moulding Frequently used injection-moulding materials include: polypropylene; polyethylene; ABS; polycarbonate; polyamide; POM; PET; PBT; PMMA; PEEK. Each material has different strengths and limitations. PP is commonly used for cost-effective components, chemical-resistant parts and living hinges. ABS is often selected for housings that require toughness and a good surface finish. Polycarbonate can provide high impact strength and transparency. POM is commonly selected for precision mechanical parts with low friction. PEEK is used in high-performance applications that require strong thermal, chemical and mechanical properties. Liquid silicone rubber is also injection moulded, but through a specialised process involving a reactive elastomeric material rather than a standard thermoplastic melt. Polymer Selection for Medical Devices It is not accurate to say that every plastic component used in a medical product automatically requires the same biocompatibility testing. Biological evaluation is particularly relevant when a device or its materials directly or indirectly contact the human body. The appropriate assessment depends on factors such as: type of body contact; contact duration; material composition; manufacturing process; sterilisation method; potential substances released from the material. Regulators including the US FDA describe this as a risk-based evaluation rather than a universal test requirement for every medical component. Polymers and RoHS Compliance RoHS restricts specified hazardous substances in electrical and electronic equipment sold in the European Union. It does not approve or prohibit entire polymer families such as ABS or polycarbonate. Instead, concentration limits apply to homogeneous materials within the equipment. A single-material plastic housing may be considered a homogeneous material. Consequently, the plastic grade—including pigments, flame retardants and other additives—must comply with the applicable restricted-substance limits when the product falls within RoHS scope. Manufacturers should therefore obtain appropriate declarations or test evidence for the complete material grade, not merely assume compliance from the polymer name. Polymer Selection and the Circular Economy Polymer selection is increasingly influenced by more than immediate product performance. European policy is placing greater emphasis on: material efficiency; product durability; repairability; recycled content; recyclability; waste prevention; producer responsibility. PwC notes that the EU Green Deal and Circular Economy Action Plan increasingly influence product design, material selection and entire value chains. PwC also highlights that extended producer responsibility can include requirements relating to recycled content, end-of-life costs and product design for recycling. For manufacturers, this means questions about a polymer may now include: Can recycled material be introduced? Can the polymer be separated from inserts or other materials? Does the formulation contain substances that complicate recycling? Can material declarations be provided? Can production scrap be reduced or reused? Is the chosen material likely to remain compliant throughout the product lifecycle? A polymer that performs well technically may still create commercial difficulties if it cannot meet future sustainability, traceability or customer requirements. Can the Same Mould Be Used with Different Polymers? Sometimes, but not automatically. Different polymers can have significantly different: shrinkage rates; melt viscosities; processing temperatures; cooling requirements; venting requirements; gate requirements; ejection behaviour; abrasive or corrosive effects. A mould developed for one material may produce dimensionally incorrect or visibly defective parts when another polymer is introduced. Changing materials may require adjustments to: gates; runners; vents; cooling channels; processing parameters; draft angles; cavity dimensions; surface finish. Material changes should therefore be evaluated before tooling is finalised whenever possible. Conclusion A polymer is a substance composed of macromolecules created from smaller molecular building blocks. The performance of a polymeric material depends not only on its chemical name, but also on its molecular architecture, molecular weight, crystallinity, additives, reinforcement and manufacturing history. For plastic manufacturing, polymer selection affects: component performance; mould design; process stability; appearance; regulatory compliance; product lifetime; recyclability; production cost. Selecting the right material is therefore one of the most important early decisions in the development of a plastic component. At TLT Manufacturing, material selection can be evaluated together with component geometry, tooling, injection-moulding requirements and expected operating conditions. This helps ensure that the chosen polymer is suitable not only in theory, but also for reliable serial production. Frequently Asked Questions What polymers are commonly used in plastic injection moulding? Common materials include PP, PE, ABS, PC, PA, POM, PET, PBT, PMMA and PEEK. The right material depends on the component’s mechanical, thermal, chemical, appearance and regulatory requirements. How do I choose a polymer for a manufactured product? Begin with the product’s operating environment and performance requirements. Then evaluate process compatibility, component geometry, expected production volume, compliance requirements, material availability and end-of-life considerations. What polymers are suitable for medical devices? Materials including PP, PE, PC, ABS, silicone and high-performance engineering polymers may be used in medical devices. Suitability depends on the device design, body contact, sterilisation process, exposure duration and applicable regulatory requirements. What polymers are suitable for electronics housings? ABS, PC, PC/ABS blends, polyamides and other engineering thermoplastics are commonly used. The final grade may also need to meet flammability, impact, temperature, electrical and restricted-substance requirements. Can recycled polymers be injection moulded? Yes. However, recycled content can affect colour, odour, flow, mechanical performance and batch consistency. The material should be evaluated through production trials and component testing. Can the same mould be used with different polymers? Possibly, but dimensional shrinkage, viscosity, processing temperature and cooling behaviour must be assessed. Tool modifications may be required.

Key takeaways: The process uses a three-station sequence to inject a preform and then inflate it, producing scrap-free parts that do not require trimming. IBM is ideal for producing containers under 1 litre with highly accurate threaded necks, while extrusion blow moulding is better suited for larger vessels such as industrial drums. Choose this process when you need small, seamless hollow containers, and rely on standard injection moulding for solid parts that require complex internal features. Injection blow moulding is a specialized manufacturing process that offers tight tolerances and high structural integrity for small containers and hollow plastic parts. Our guide explains how the method works and compares it with other variations, such as extrusion blow moulding. We will also cover the materials, applications, and parameters you need to consider for your next production run. What Is Injection Blow Moulding? Injection blow moulding produces hollow parts by first injecting a polymer preform over a core pin, then transferring it to a blow cavity for inflation. Unlike extrusion blow moulding, which drops a thick tube known as a hollow parison, this method uses a precisely injected preform. It allows for much higher precision when forming intricate neck details. Manufacturers primarily use this method for containers under one litre. It reliably achieves the tight tolerances and precise threaded necks required for pharmaceutical and cosmetic packaging. How the Injection Blow Moulding Process Works The IBM process occurs across three stations on an indexing rotary table. It moves automatically from injection to ejection without manual handling. Stage 1 - Injection. The machine injects molten plastic around a core rod inside the injection mould. It forms a preform with a fully finished neck and a controlled wall thickness. Stage 2 - Blowing. The rotary table indexes the core rod and preform to the blow station. By blowing air through the core rod, the system inflates the hot plastic against the walls of the blow mould, ensuring an even material distribution. Stage 3 - Cooling and ejection. The part cools in the mould before it opens. A stripper plate then pushes the finished container off the core rod and onto a conveyor. Because all three stations operate simultaneously, the process achieves fast cycle times. Depending on container size, production moulds can range from a few cavities up to slightly more than a dozen, producing finished parts that require no secondary trimming. Injection Blow Moulding vs Injection Moulding Although they share basic principles, these processes serve distinct needs. Injection blow moulding creates seamless hollow containers, while standard injection moulding produces solid parts and complex geometries. Feature The two-stage process Conventional moulding Output type Seamless hollow containers Solid parts and open geometries Typical applications Small bottles, pharmaceutical vials, cosmetic jars Housings, gears, brackets, structural components Tooling complexity High (requires preform cavities, blow cavities, and core rods) Varies (simple two-plate moulds to complex multi-action tools) Size range Typically restricted to containers under 1 liter Ranges from microscopic parts to large automotive body panels Wall thickness Controlled by preform design and uniform compressed air expansion Defined exactly by the gap between the mould core and cavity Cycle time Fast, limited primarily by the cooling time of the preform neck Varies heavily based on wall thickness and material Scrap rate Near zero, as the process creates no pinch-off flash Low, though cold runner systems require regrinding The standard injection molding process is required for solid components, asymmetrical profiles, and parts that require internal features such as threaded inserts or overmoulded grips. Materials Used in Injection Blow Moulding Material selection requires balancing application needs, such as chemical resistance and visual clarity, with processing capabilities and recyclability. While primarily associated with injection stretch blow moulding, polyethylene terephthalate (PET) is occasionally used in standard IBM for premium cosmetic containers that require high clarity and good gas barrier properties. HDPE and LDPE are the most common resins used in IBM. They are frequently chosen for pharmaceutical and personal care packaging due to their excellent chemical resistance and moisture barriers. Polypropylene (PP) offers excellent moisture resistance and fatigue strength, making it suitable for personal care packaging and containers requiring flexible living hinges. PVC is sometimes used for its unique chemical resistance, but it presents distinct processing challenges due to its poor thermal stability. Manufacturers are increasingly incorporating post-consumer recycled (PCR) resins and bio-based plastics. However, because the injection stage of IBM requires highly consistent melt flow indexes, processing PCR materials requires careful parameter control and higher-quality resin sorting than the slightly more forgiving extrusion processes. Main Applications of Injection Blow Moulding Injection blow moulding is widely used in the packaging sector to produce small containers that require precise dimensions and excellent visual finishes. Packaging manufacturers use IBM to produce pharmaceutical items like pill bottles, eye-drop vials, and diagnostic reagent containers that require secure, leak-proof seals. The cosmetics industry uses this process for small items such as hotel amenity bottles and high-end lotion containers, where visual quality is critical. In the food and beverage sector, IBM is ideal for small-volume packaging like concentrated flavouring dispensers and single-serve nutritional shots. Chemical and laboratory suppliers use IBM to manufacture small reagent bottles and sample packs that require precise threading to prevent hazardous leaks. Because the neck is formed in an injection cavity rather than pinched off in an extrusion mould, IBM produces seamless threads that provide superior seals for caps and closures. How to Choose Between Injection Blow Moulding and Injection Moulding The choice between these two processes depends entirely on the physical properties of the part, primarily whether the design calls for solid forms or hollow shapes, its size, and its intended function. Choose injection blow moulding when you need to produce small hollow containers with highly precise necks. Standard injection moulding is required for solid parts, open geometries, intricate internal walls, and structural components. Standard injection moulding allows for insert moulding and overmoulding, which are essential when integrating plastic parts directly with metal hardware or electronic components during the moulding cycle. If the component is not a hollow container, standard injection moulding is the correct choice to achieve precise dimensions, complex shapes, intricate features, and high surface quality. Partnering with an experienced manufacturer like TLT ensures your injection-moulded and blow-moulded parts meet strict ISO quality standards and regulatory requirements. Conclusion Selecting the right plastic manufacturing process requires understanding exactly how each method forms the material to meet your specific design requirements. Unlike extrusion blow moulding, which drops a continuous parison in the form of a hollow tube, injection blow moulding forms the neck in a solid injection cavity first, ensuring high dimensional accuracy before inflating the bottle. The strict control over the neck finish and sealing surface makes it the industry standard for pharmaceutical vials, cosmetic jars, and containers that cannot risk a leak.

For our clients, this is a chance to expand manufacturing into a second region without the headache of onboarding a new supplier. Same team, same processes, same quality standards — still TLT Manufacturing, just on another continent. Why Vietnam? Proximity to the Asian electronics supply chain means shorter lead times on components and raw materials, competitive input costs, and tariff-advantaged access to Asian markets through Vietnam's free trade agreements (CPTPP, RCEP, EVFTA). For clients serving Asian customers — or diversifying away from single-region risk — this changes the math. The facility at a glance: 🔹 6,500 m² production floor 🔹 2 SMT lines + 2 THT lines 🔹 Laser marking, X-ray inspection, full QC suite 🔹 60 employees already on board (110 by the end of the year) 🔹 Test production runs successfully completed At TLT Manufacturing, flexibility has always been our differentiator — adjusting our processes around what each client actually needs. With Vietnam now operational alongside our Lithuanian facilities, that flexibility extends to geography itself: manufacture in Europe, in Asia, or split between both, with the benefits each location brings. One partner. Two regions. Endless options. Moments from opening:

Electronics manufacturing services — commonly known as EMS — refer to the outsourced design, assembly, testing, and distribution of electronic components and assemblies on behalf of original equipment manufacturers (OEMs). Rather than building products in-house, OEMs partner with EMS providers to handle part or all of the production process. How EMS Works An EMS provider typically offers a range of capabilities across the product lifecycle. This begins with design support and prototyping during the new product introduction (NPI) phase, followed by printed circuit board assembly (PCBA), system integration, functional testing, and final packaging. Many providers also handle procurement, supply chain management, and aftermarket services such as repair and refurbishment. The core production process centers on surface-mount technology (SMT) and through-hole technology (THT), which are the two primary methods for mounting electronic components onto circuit boards. Modern EMS facilities use highly automated SMT lines capable of placing thousands of components per hour with micron-level precision. Why Companies Use EMS Providers Outsourcing electronics manufacturing allows OEMs to reduce capital expenditure, accelerate time to market, and access specialized expertise without maintaining their own production infrastructure. It also provides scalability — companies can ramp production volumes up or down based on demand without carrying the fixed costs of idle equipment and factory space. Industries that rely heavily on EMS include telecommunications, automotive, medical devices, industrial automation, aerospace, and consumer electronics. Quality and Certification Reputable EMS providers maintain internationally recognized certifications such as ISO 9001 for quality management, ISO 13485 for medical devices, and IATF 16949 for automotive. These certifications ensure consistent, traceable, and auditable manufacturing processes — a critical requirement for regulated industries. The Growing Role of EMS As products become more complex and supply chains more global, the EMS industry continues to expand. Companies increasingly look to EMS partners not just for assembly, but for end-to-end manufacturing solutions that span from concept through to delivery.

Today we take a big step for European manufacturing resilience and IP security. In the High-Tech Hill technology park (Vilnius, Lithuania), we’re cutting the ribbon on four new TLT plants — all in one place:   TLT PCB — a new, ultra-modern PCB factory ; the first new PCB facility built in Europe in two decades. TLT Electronics — our new electronics manufacturing facility, 3× larger than the previous site. TLT Mechanics — a plastic injection moulding & mechanical engineering factory, 2× larger than before. A new electronics component assembly facility to accelerate time-to-market and scale.    Why this matters   TLT offers end-to-end, vertically integrated EMS — from PCB manufacturing to final product assembly , with plastics, mechanics, and SMT in between — all on one secure campus in Lithuania, EU . For customers in defense, medical, and automotive sectors, this single-site model strengthens intellectual property protection , supply-chain control , and quality assurance .   Scale at a glance   €320M total investment 1,370 new jobs 82,100 m² of new manufacturing space   With these openings, TLT’s annual capacity rises from 10M to 30M electronic devices, supporting our path to €1.5B in near-term revenue. And we’re only at the first stage of High-Tech Hill — by 2032, this park will help position electronics among Lithuania’s Top 3 industries .     An invitation   To our customers and partners: thank you for your trust — let’s build the next generation of European tech together. To engineers, operators, and problem-solvers: if you want to shape the future of secure, high-volume manufacturing in Europe, join us in Vilnius . Head of AGP Investments, founder of Teltonika and TLT Arvydas Paukštys New Teltonika EMS factory - electronics manufacturing services at Svylos st. 16, Vilnius Head of AGP Investments, founder of Teltonika and TLT Arvydas Paukštys and Lithuania's president Gitanas Nausėda Plastic and mechanical components factory at Svylos st. 6, Vilnius Electronic components factory at Svylos st. 8, Vilnius TLT PCB - printed circuit boards - factory at Gaujos st. 4, Vilnius From the left - CEO of Electronics Components Factory Dovydas Rupšys, CEO of TLT PCB Tomas Auruškevičius, CEO of Teltonika EMS Simas Rutkauskas and CEO of Plastic and mechanical components factory Arnas Strioga

TLT is preparing to open several new manufacturing facilities, expanding its ability to support partners across plastics, electronics, and PCB production. This investment reinforces TLT’s role as a full-service manufacturing partner, bringing together design, tooling, production, and assembly under one roof. One of the new additions is a 22,100 m² facility focused on plastic and mechanical component manufacturing. It’s built to handle a wide range of materials, including conventional plastics, rubbers, and technical polymers. The site combines in-house tooling, plastic injection moulding, and automated production systems to streamline processes and improve overall efficiency. New 22,700 m² electronics assembly plant supports a full range of production stages from prototyping to serial production and final box-build. The facility includes advanced surface-mount and through-hole technologies, allowing it to handle both simple and complex electronic assemblies. Launching a 33,000 m² printed circuit board (PCB) factory. This site is equipped to manufacture a wide variety of board types, including multi-layer and high-density interconnect (HDI) designs. It features advanced processes such as vertical continuous plating (VCP), as well as an in-house innovation lab to support rapid development and customization. The factory can manage both fast-turn prototyping and ongoing production, offering flexibility for growing or evolving product lines. By bringing all these capabilities together, TLT offers a vertically integrated model that reduces lead times, lowers risk, and improves supply chain control. Partners benefit from having a single point of contact for multiple processes and from the stability that comes with consolidated manufacturing operations. This model is especially valuable for companies operating in fast-paced or highly regulated industries where speed and quality are critical. All new facilities are set to be operational soon. TLT is now opening discussions with new and existing partners across sectors like electronics, industrial equipment, medical devices, and beyond. The company’s mission remains focused: to make it easier for partners to bring products to life, faster and with confidence. Its vision is clear. To be the go-to partner for full-service manufacturing. All you need, in one place. Close, fast, reliable. For partnership opportunities or to learn more, reach out to directly.

Our presence extends to 27 countries worldwide, complemented by three manufacturing plants located in Vilnius and Molėtai. We will soon gain four new production complexes. We have exciting news for our partners – starting this summer, we plan to initiate trial production batches of PCBs, and by the end of the year, we will fully launch new factories for electronics assembly, plastic, and mechanical components. This phase of our expansion will enable us to triple our production capacity from 10 to 30 million units in the near future, ensuring we are fully equipped to support our clients, even in the largest projects worldwide. VALUE FOR TLT PARTNERS Printed Circuit Board (PCB) Manufacturing Facility: Assurance of high-quality products; Accelerated research and development along with new product integration into the partner portfolio, providing a competitive speed advantage; Essential product components produced in Europe. New Electronics Assembly Facility: Enhanced production capacity leading to quicker order fulfillment; Faster adaptation to market and partner demands. Plastic and Mechanical Component Manufacturing Facility: Vertical integration in a single location ensures supply chain stability for partners; Specialized production for specific products results in superior material and assembly quality, tailored to meet individual partner requirements. Electronics Assembly Facility: Focused manufacturing for uniquely specialized defense-related products. The overarching aim of these four initiatives is to achieve complete control over the production value chain, allowing for faster product development, reduced reliance on external suppliers, and the highest quality assurance for manufactured products. In the near future, 4,000 specialists will be part of the company group, playing a vital role in the successful growth of our partners.

Recently, our manufacturing facility has received new equipment – a new robotic assembly line. Additionally, we are sharing some planned equipment upgrades for this year. Together with a new electronics manufacturing facility and PCB factory construction in progress, we continue to expand our manufacturing capacity by adding new equipment to the production floor. New robotic assembly line For one of our contract manufacturing partners, the 4th robotic assembly line has been installed at our facility. This line comprises several assembly cells interconnected by conveyor belts. Each cell is dedicated to a specific box-build operation. Equipped with robotic manipulators, these cells perform precise actions, including transferring device housings, placing necessary components, inserting PCBAs fitting device enclosures, and others. After each step, a camera conducts quality control before advancing the device along the conveyor belt to the next stage. Upcoming upgrades Robotic Testing system In the coming year, we will introduce additional testing equipment onto the production floor. Testing represents one of the most critical and time-consuming steps in electronics manufacturing. To enhance efficiency and speed in this process, we employ testing robots. These systems feature two robotic hands and can accommodate 16-24 testing fixtures. The robotic cell is divided into two sides, each capable of testing a specific product. Firmware is flashed before testing to ensure optimal performance. SMT Pick and Place Machines By the second and third quarters of 2024, we will have added two more SMT lines, comprising 10 operational lines by the end of the year. SMT pick and place machines serve as the foundation of electronics manufacturing. In our operations, we utilize the smallest SMDs measuring 0201 (0.6 x 0.3 mm) and the largest at 2512 (6.9 x 6.3 mm). Additionally, we mount larger connectors and modules. These precision machines can assemble small chips, large ICs, and other complex components with great accuracy. Teltonika EMS service portfolio Our facilities currently offer a comprehensive range of services, including plastic injection molding, electronics assembly, testing, and box-build. Leveraging our sourcing power, R&D capabilities, manufacturing expertise, and additional capacity dedicated to our partners, we assist in successfully implementing and expanding their projects.

Permission to establish a 27 100 square metres size facility was granted. The 3-floor building will be equipped with the latest technology for plastic parts and custom mould production. It will be one of the largest factories of this kind in Lithuania.    The new facility will be in the capital city - Vilnius, in the Teltonika High-Tech Hill, surrounded by electronics and PCB manufacturing buildings. The start of construction of the plastic moulding and tooling services factory marks the continuation of a vertical integration strategy aimed at offering customers all the most important electronics manufacturing processes under one roof. This approach keeps shortening the supply chain and reducing dependency on the suppliers.   Teltonika will employ around 300 various experts like mechanical and process engineers, automation specialists, equipment adjusters, and more who will operate the latest equipment.  According to the President of the Teltonika company group Arvydas Paukštys, this will help to ensure even better product quality and reduce the launch time of new products by half. With the latest automated equipment operators will be able to combine and mould components from different materials such as rubber, plastic, metal, and more. Sustainability has been the top priority in the construction plans. All Teltonika’s facilities are operated using renewable energy sources and this will be no exception. Most of the plastic waste will be recycled and returned to the production process. The new building will meet the necessary environmental requirements.

Our new manufacturing factories are set to open in 2025 and we are excited to reveal the emerging real picture of the buildngs. The two buildings consist of PCB and electronics manufacturing facilities, which together expand our manufacturing space by more than 50 thousand square metres.  With the addition of manufacturing complexes, we continue to proceed the vertical integration approach. Such a strategy enables us to meet the growing demand and provide the highest quality services for our contract manufacturing partners. Here is more information about the facilities. PCB Factory Printed circuit boards are an essential part of the electronics manufacturing industry. Reacting to potential risks in the market, we are establishing the first PCB factory in Europe after two decades, which will open its doors in the first half of 2025. The facility is designed to include highly automated equipment from Japan, Germany, and Italy and plans to employ around 250 specialists.  Electronics manufacturing capacity Opening its doors in the first half of 2025 is also our new manufacturing facility for electronics.  This automated and modern factory includes 10 electronic assembly lines, 20 testing lines, 4 packaging lines, a modern robotic warehouse, and laboratories. Additionally, employing around 700 skilled specialists to operate the manufacturing process. See it yourself:

We welcome you to meet us at exhibition close to your location and see firsthand how our team's skills can address your manufacturing requirements. During the exhibition, we'll provide insights into our ambitious strategies for PCB manufacturing in Lithuania, emphasizing our dedication to enhancing the supply chain and backing local production. Focus on PCB exhibition is a one-shot opportunity to meet European leaders in the industry. In response to the increasing demand for PCB and PCBA, the event offers opportunities to explore their features with potential partners in the market. Meet our team to learn about plans for an upcoming PCB factory in Lithuania, highlighting the commitment to streamlining the supply chain. Stay tuned for upcoming details on other exhibitions

At the Teltonika Technology Centre, we have recently integrated the Kardex storage system. This system comprises four Kardex cabinets, with a total of 1904 distinct component storage locations, ensuring seamless storage and retrieval of electronic components. How We Use Kardex Vertical Buffer Module (VBM) The Kardex system employs automated storing processes. The vertical lift module inside the system facilitates the movement of boxes, efficiently storing and issuing the required components. This results in a streamlined workflow, minimizing downtime and boosting overall productivity. The VBM is integrated with Teltonika EMS's internal ERP systems. When components arrive at our facility, the component reels or trays are marked with stickers. After passing the quality check, they are inserted into the Kardex system, and their location is encoded. So, when the SMT line needs to be loaded for a new project, the Surface Mount Technology operator can easily collect all the required components according to the bill of materials for the project. Benefits of the Kardex Storage System As our partner and project portfolio expand, the Kardex system will increase the quality of our manufacturing process while simultaneously leaving space for project development. Component Freshness Assurance Kardex operates on a first-in, first-out (FIFO) principle, ensuring that components are used from the oldest to the newest. This guarantees that stored components maintain optimal functionality and shelf life. Controlled Environment Being stored in Kardex, electronic components are ensured to have the best environmental solutions. Teltonika EMS Service Portfolio Our facilities currently offer services for plastic injection moulding, electronics assembly, testing, and box-build. Our partners successfully implement and expand their projects thanks to our sourcing power, R&D, manufacturing know-how, and extra capacity dedicated to partners.