COMMITTED TO PROGRESS
and eliminating the status quo.
DESIGN FOR MANUFACTURING SERVICES For medical devices
We understand the critical importance of early collaboration for successful medical device development. Regulatory hurdles after a device is launched can be costly and time-consuming. That’s why having the right partner is key. Our in-house Degreed Plastics Engineers offer Design for Manufacturing (DFM) analysis upfront. With expertise in precision tooling, plastic processing, and product development, we optimize part designs to meet your specifications, while finding opportunities to reduce cost through cycle time, material waste, and overall mold efficiency. Each proposal is meticulously reviewed to ensure the successful launch of your medical device.
DESIGN FOR MANUFACTURING
We are experienced with the latest CAD software including SolidWorks, Pro-Engineer, Moldflow and more. Our goal is to provide our customers with a holistic & objective review of their device during the quoting phase. We also explore ways to reduce cost through part optimization, material selection, mold design, and manufacturing.
MOLD FILLING SIMULATION
At Plastikos, we have a thorough understanding of mold-filling simulations to further optimize gate location, wall thickness, mold orientation, weld lines, etc. Our plastics engineering group will work your device team to further improve potential issues through mold simulation.
3D Printing Technology
We implement state-of-the-art 3D printing expertise through Markforged technologies to provide our clients with real-life samples during the development phase of their devices.
IN-HOUSE CT SCANNING
We utilize the latest in-house CT scanning technology to provide our customers services such as: reverse engineering, non-destructive testing, measurement analysis, etc. Often, we can take a full assembly of our customers’ product to help them analyze and wide variety of requests utilizing this technology.
DESIGN FOR MANUFACTURING TOOLS
FOR MEDICAL INJECTION MOLDING
Part Design for Plastic Manufacturing is crucial for the success of your medical device. During the Design for Manufacturing review with your medical device supplier, elements like uniform wall thickness, draft, structural rib design, gate location, etc. should be carefully scrutinized. Neglecting these features can lead to downstream issues related to part quality, dimensional instability, reduced yields, and cost.
Upfront analysis via mold filling simulations is an excellent tool to help identify where certain areas of the part design need addressed before starting the mold design and subsequent fabrication. During this mold filling analysis, we will work our clients to optimize the part geometry, identify gating location(s), simulate cooling channels, address areas of potential warp and deformation, and review expected processing conditions.
Additionally, we leverage Markforged 3D printing technology to offer clients real-life samples, enhancing the understanding of a device’s appearance, fit, and possibly function. This cutting-edge technology enables rapid sample production, expediating part design adjustments during the device’s development phases.
CUTTING-EDGE CT SCANNING
FOR MEDICAL DEVICE MANUFACTURING
CT scanning plays a crucial role in product development and production inspection, providing micron-level accuracy for finished parts. This non-destructive testing method helps in detecting key assembly challenges like leak paths, form and fit issues, and sealing surfaces.
Moreover, CT scanning is valuable for reverse engineering, especially in cases where part drawings do not align with the finished device. By comparing scanned parts to 3D models, a correlation study can be conducted to assist our clients in making necessary adjustments.
Beyond DFM analysis and reverse engineering, CT scanning enhances measurement accuracy, reduces inspection time, and minimizes human errors during the mold qualification process. A technology-driven approach that ensures precision and efficiency in every step of the process.
Account Spotlight
GLAUCOMA TREATMENT
THE INITIAL CHALLENGE
We were approached by our client who had developed a new delivery device for Glaucoma treatment. The device was relatively new to the market, and volumes were expected to grow exponentially. During the initial product evaluation, we learned the first-generation design was plagued with considerably high warpage and deformation, which led to downstream assembly challenges and high scrap rates for our client.
We believed improper gating location was the main contributor behind these high levels or warpage. The original part design was gated in the thinnest wall, leading to insufficient packing once the gate had frozen. Our Plastic Engineering team conducted a series of mold filling simulations to identify which gate location would yield the lowest warpage. Ultimately, we determined a dual valve gated approach would be necessary to fill the length of the part, while minimizing warp and deformation, resulting in the following:
- Dual valve gated approached reduced warpage from 0.025" to less than 0.006" with the redesigned runner and gating system.
- Our customer was able to redesign their product's assembly features to be much more efficient because of the reduced part deformation.
- Runner waste was eliminated resulting in less material consumption, faster cycle time, and lower part cost.
Utilizing objective mold-filling simulations and proper Design for Plastic Manufacturing techniques proved to be essential to address both quality issues as well as cost associated from raw material and assembly.
PIONEERING THE FUTURE OF MEDICAL DEVICE MANUFACTURING WITH PRECISION, CARE, AND INNOVATION
If you’re ready to elevate your project with top-tier injection molding services, contact us today.
