Downloaded 15 times
![• Model vs. Molded part
• Iden4fy failure modes (PFMEA)
• Prototype-bridge tooling – high cavita4on produc4on
• Son tooling vs. Hard tooling
• Exact execu4on with work piece accuracy of:
.000042” [~ 1µ, 0.0010668 mm]
• Sarix 3D EDM milling
• All maintenance performed in-house
• EOAT in-house – Automa4on
11
Micro-Edge Tooling
Micro Tooling](https://image.slidesharecdn.com/2016-04-07nicmdo-160405130120/85/Challenges-Emerging-Solutions-through-Micro-Molding-11-320.jpg)
![• Reviewing what is possible
<R.001”
.002” wall thicknesses
250:1 aspect ra5os
Zero dra]
• Micro Medical Applica4ons:
Endoscopy
Laparoscopy
Abla5on
Brachytherapy
Drug Delivery
Fixa5on
14
Micromolding Opportuni4es
Material: 30% GF Nylon 12
Challenge: U4lize the micro molding process to insure a polymer rich
surface which would not allow a possible electrical leak path as well shut
off on delicate wiring ranging from .010” up to .015”. Handling 6-8 n of
delicate wire assembly.
Descrip5on: Electrocautery device used in a new laparoscopic platorm.](https://image.slidesharecdn.com/2016-04-07nicmdo-160405130120/85/Challenges-Emerging-Solutions-through-Micro-Molding-14-320.jpg)
Uploaded byDesign World
Challenges & Emerging Solutions through Micro Molding
The document outlines a webinar focused on medical micro molding, featuring experts discussing the challenges and solutions in micromolding for medical applications. It highlights the capabilities of MTD Micro Molding, including material selection, production techniques, and case studies demonstrating successful applications in the industry. The session also emphasizes the importance of advanced technologies and methodologies for achieving high precision and quality in micro medical devices.
More Related Content
Similar to Challenges & Emerging Solutions through Micro Molding
Challenges & Emerging Solutions through Micro Molding
- 1.
- 2. #MDOWebinar q This webinarwill be available afterwards at www.medicaldesignandoutsourcing.com & email q Q&A at the end of the presentation q Hashtag for this webinar: #MDOWebinar Before We Start
- 3. #MDOWebinar Introducing the FeaturedSpeakers MODERATOR FEATURED SPEAKER Nic Abraham Senior Editor Medical Design & Outsourcing Brian Matachun Director of Technical Sales MTD Micro Molding
- 4.
- 5. 5 About Us … • Experience: 40+ years of miniaturiza4on; tool making à molding • Focus: Engineering Focus with a Manufacturing Objec4ve • 4 class 100k cleanrooms; 11 self-contained work cells • 100% Medical • 100% Micro • Development programs à Millions of produc4on parts • Ver5cal Integra5on: • 100% In-house tooling • Technology: • Con4nuous investment • Necessary Credits • ISO 9001:2008 • ISO 13485 (July 2016) • Processor of the Year Finalist 2015 MTD Introduc4on Part Weight . 00000313gms
- 6.
- 7.
- 8. Material Selec4on Thermoplas5cs Thermoplas4cs are polymers that become pliable and moldable above a specific temperature, and returns to a solid state upon cooling. Any thermoplas5c material, with proper tes5ng, can be used for a medical implant. A SELECTION WE WORK WITH: 8 • ABS (Acrylonitrile Butadiene Styrene) • ABS + PC • Acetal (including Barium Sulfate- filled Acetal) • COC (Cyclic Olefin Copolymer) • COP (Cyclo Olefin Polymer) • Hydrogels • LCP (Liquid Crystal Polymer) • Nylon (Polyamide PA) • PEBAX (including Barium Sulfate0fille PEBAX) • PEEK (PolyEther Ether Keytone) • PEI (PolyEthermide, Ultem) • PEIK (Linear PolyEthylene) • PELLETHANE • PBT (Polybutylene Terephthalate) • PEKK (Polyaryletherjetone, including Barium Sulfate-filled PEKK) • PET (PolyEthylene Teraphthalate) • Polycarbonate (PC, including PC / ABS Blends and Glass-filled PC) • Polymide • Polypropylene (PP) • Polysulfone (PSU) • Polyurethane (flexible) • Polyurethane (rigid) • Tecothane • Tecoflex • TPR (ThermoPlas4c Rubber) 25 of the MORE COMMON THERMOPLASTICS RUN at MTD MICRO MOLDING:
- 9. Bioresorbables Bioresorbable materials are popular in micro medical applica4ons as the materials can dissolve/absorb into the body. IDEAL FOR: • Medical bioabosorbable anchors • Implantable staples • Bioresorbable micro-plugs • Micro-screws A SELECTION WE WORK WITH: 9 • Purasorb PLG 8531 (85/15 L-lac4de/glycolide copolymer) • Purasorb PLG 8218 (85/18 L-lac4de/glycolide copolymer) • Purasorb PLG 1017 (10/90 L-lac4de/glycolide copolymer) • Purasorb PDLG 5010 (50/50 DL-lac4de/glycolide copolymer) • RESOMER L210S (Poly-L-lac4de) • RESOMER LR 706 (Poly-L-lac4de-co-D,L-lac4de) 70:30 • RESOMER LR 708 (Poly-L-lac4de-co-D,L-lac4de) 70:30 • RESOMER LR 704 (Poly-L-lac4de-co-D,L-lac4de) 70:30 • RESOMER RG 509 S (Poly-L-lac4de-co-glycolide) 50:50 • P4HB-based (poly-4-hydroxybutyrate) • PCL-based (poly epson-caprolactone) • PLGA-based (poly lac4de-co-glycolide) • PLLA-based (Poly-L-Lac4de) • Other (Customer Proprietary Bioresorbable Materials) Material Selec4on
- 10. • MICRO-FILL: Specialized micro molds for tes4ng material flow of different materials and fillers. The data from the flow tes4ng is u4lized to predict feasibility of product features when reviewing new part designs. • MICRO-FLOW: Micro-Plaque to evaluate flow of materials into various thicknesses. • MICRO-RUNNER: A tooling based strategy that examines flow proper4es in the runner system to reduce scrap. 10 Micro Design Micro Technologies
- 11. • Model vs. Molded part • Iden4fy failure modes (PFMEA) • Prototype-bridge tooling – high cavita4on produc4on • Son tooling vs. Hard tooling • Exact execu4on with work piece accuracy of: .000042” [~ 1µ, 0.0010668 mm] • Sarix 3D EDM milling • All maintenance performed in-house • EOAT in-house – Automa4on 11 Micro-Edge Tooling Micro Tooling
- 12. • Overmolding and insert molding • True zero-defect • In-process vision inspec4on • Screw-over plunger • RJG eDART – sensing & control integra4on • Lights-out manufacturing • Custom tray and packaging • Custom End of Arm Tooling (EOAT) o Pick and place 12 100% Cleanroom Molding Micro Molding
- 13. • Robust valida4on process - standardized • IQ/MT1, MT2, OQ/PQ methodology • Custom in-house fixturing • Non-contact fully automated OGP measurement systems • CT-Scanning • Gauge R&R1 (analysis of the effec4veness of the measurement system) • IV, DSC, and Tensile Tes4ng • Standard capability goal of 1.33 Cpk 13 Micro Metrology and Tes5ng 1 Gage Repeatability and Reproducibility Micro Metrology
- 14.
- 15. CASE STUDY: Stairs PROBLEM: Failure of Addi5ve Mfg for Rapid Prototyping • 16µ layer thickness & 25µ step-over = fuzzy parts • Finished parts brivle and broke when flexed • Not suitable except as a model for display SOLUTION: • MTD built a single cavity tool • Useful for prototyping • Acceptable for clinical trials • Scalable for produc4on 15 ~ .040” ~ .007 X .006” Each stair-step is approx. diameter of a human hair Compe4tor’s avempt, using 3D prin4ng technology in a “polypropylene-like” prin4ng grade polymer MTD’s micromolded acetal part Detail of MTD’s micromolding
- 16. CASE STUDY: Bioabsorbable Screw PROBLEM: • Goal= bioabsorbable product • 6+ months of failure in thermoplas4c (surrogate) • S4ll unable to fill in ANY thermoplas4c filling “violently” • Lost market share, delayed entry to market SOLUTION: • Unique approach to tool design to fill “gently” • MTD 4meframe: 4 weeks PHASE II RESULT: • Produc2on capability: over 170K per week • 7.5% average IV loss • 38% cost reduc2on over 4 years 16 RESCUED
- 17. CASE STUDY: Drug Delivery PROBLEM: • 4 piece manual assembly • Worst plas4c design part ever • Leakage between assembled Parts • Standard manufacturing was not possible • Tolerances • High cost SOLUTION: • Mold all components together at once • MTD 4meframe: 8 weeks • Scalability to produce 50MM • 24/7 (lights out) • Custom packaging • Cost reduced by 50% • I.D. Cpk=4.5 17 RESCUED .0008” Wall Thickness
- 18. • Only Molder who focuses on Micro Molding • Only Micro Molder in North America solely focused on Medical • Only Molder in North America with 3D EDM Milling Technology • 90% documented on 4me project comple4on • 20% of MTD successes have been FAILURES by others • 30% of successes have been NO QUOTED elsewhere 18 Differen4ators Medical micromolding is what we do. And all we do. Material: Carbon Filled PEEK Dimensions: Micro Overmolding over a .031” diameter stainless steel rod. Descrip5on: Micro Overmolding and Carbon Filled PEEK Micro Molding materials with a 400 degree F mold temperature both present many challenges.
- 19. #MDOWebinar Questions? MODERATOR FEATURED SPEAKER NicAbraham Senior Editor Medical Design & Outsourcing nabraham@wtwhmedia.com @NicsMedTechNews Brian Matachun Director of Technical Sales MTD Micro Molding bmatachun@mtdmicromolding.com @MTDMircoMolding
- 20. #MDOWebinar q This webinarwill be available at www.medicaldesignandoutsourcing.com & email q Tweet us! #MDOwebinar q Connect with Medical Design & Outsourcing q Discuss this on EngineeringExchange.com Don’t Forget!
- 21.