A large number of the medical tools you see in your clinic or doctor's office ' such as PPE, syringes, IV tubes, and more ' are made using plastic injection molding due to the materials and process' numerous benefits.
For these medical devices, the design phase is a critical time in creating a potentially life-saving product ' which is why there are several factors to consider when making injection molded medical parts.
If you're interested in venturing into this industry, you might be wondering what these are. We've identified eight of the most important considerations to include in your design process, along with our advice for gaining advantages for your parts.
The primary driver in designing your injection molded medical parts is their intended functions. Consider the end-use and end-user. Are you designing something that is meant to carry fluids? Or is it an implant meant to last several years? Perhaps it is a lever attached to some medical equipment? Different functions imply various designs.
Even tools with the same general function will have distinct variations. For example, prosthetics have the same general function (i.e. to replace a body part), but a hand prosthetic is vastly different from a leg prosthetic.
The second thing to consider is the required longevity. There are two types of plastic tools in the medical industry: single-use products and sterilizable products. Single-use products are meant to be disposed of after use, which gives you more leeway in material choice.
Items meant to be used multiple times over need to be sterilized to be medically safe, which means the material you choose needs to withstand repeated exposure to the sterilization method(s) chosen.
For example, the medical part could be steam-sterilized. This means that the resin you choose for your part will need to be resistant to heat and hydrolysis. The part will also have to be compatible with the chosen method. This could mean removing any unnecessary niches on the tool to allow for proper cleaning, along with other design changes. These are the kinds of things to consider when designing a medical part meant for repeated use.
Third, consider the environment that this medical part will be used in. For example, parts that are to be used in a laboratory may need to withstand friction and impact, as they will be handled by several people throughout their lifetime.
Another example is an implant, which is designed to be placed inside a patient's body. The plastic part should therefore be able to handle liquids, heat, movement, and corrosive substances.
Additionally, the implant's design needs the patient's comfort and safety in mind. The design and materials you choose for your part should factor in the environment it will be exposed to.
When it comes to medical parts, those that can easily break or shatter aren't suitable for use. They are an inconvenience and pose health hazards not just for the patient, but also for the medical professional handling the tool. As such, your design should consider how durable your part needs to be, and which materials offer resistance to breakage and shattering.
There are several different resins used in injection molding for medical parts. From silicone to polyetheretherketone (PEEK) to thermoplastic elastomers (TPEs), the choices are almost endless.
With that wide selection of materials, there is a wide range of bio-compatibilities and mechanical properties. Though you might think that an extensive list of choices makes it easier, choosing the best resin is more complicated than it seems.
For example, you might find that several resins fit your needs. What you should consider in that case is how effective each one is. For example, two resins might be shatterproof, but one is more durable against wear and tear. Another thing to consider is availability. One resin might seem perfect for the job, but it is difficult to source. As a result, your costs shoot up ' something you should avoid.
To make high-quality parts and reduce the need for extensive prototyping and revising, you need to consider how complex your design ought to be. Is your design overly complicated? Did you consider all the basic factors of manufacturability?
A very complex design does not mean that it is a good one ' it might just mean you're taking more steps than you should. To make a fit-for-use part and make your injection molding process consistent, your design should meet your demands practically. Consulting with your injection molding partner and their engineers should help you make smart adjustments.
Ultimately, you should consider how your medical parts will be priced once your design, materials, and injection molding process are factored in.
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Ideally, your products should be able to compete with the value and price of others on the market. Your pricing is dependent on your design ' more complex designs, the use of certain machines, and tooling options can increase costs significantly.
However, if you are making thousands of parts, consider expensive mold materials and features for your injection molding. While these have a larger initial investment, they pay for themselves in long, high-volume runs due to time and material savings. If you strike a balance between your tooling investment and volume production, you can get a bigger return on your investment. You can also ask your injection molding partner about ways they can help you reduce your overall costs.
Simply put, the skill and capabilities of an injection molding partner differ from one to the next. Not all companies are equipped to offer the same solutions. As such, you should consider the following questions when choosing your partner:
All of these considerations can lead to a partner who can offer cost-effective, high-quality solutions to your project specifications.
Injection molded medical parts have several constraints and requirements that need to be incorporated into different designs to ensure their usability and success.
Having processed many projects of this nature, Richfields' expertise can help your team avoid common mishaps, enhance your design, and ensure consistent and trustworthy services. Take a look at our capabilities here, or send us a message today to learn more about how we can assist you.
Plastic injection molding is an extremely versatile method of producing plastic parts. Due to its multiple advantages, it is preferred over other methods of plastic molding. It is an efficient, more reliable method of production and has been a standard process for high-volume components. As one of the many individuals looking to use plastic injection molding for different projects, you may wonder if there are plastic injection molders near you? Outlined below are some of the most common questions asked about injection molding.
Aside from being one of the most obvious questions, it is also very important because the actual model represents the most significant expense in the entire production process. Individuals should consider working with precision molds made from high-quality steel because they last for years. That said, it is important to note that many factors contribute to the cost of a mold in a custom plastic injection mold project. Ideally, the molder should provide the final price tag based on all the considerations made.
Working with a certified supplier who is committed to quality and is open to continuous improvements ensures that a project is accurately done. Every person looking to work on a plastic injection molding project should make sure to work with a manufacturer who has attained the highest standards in the industry. Since injection molding is a popular method, there are countless manufacturers to choose from so there is no excuse for accepting anything less than excellent work.
There are a wide variety of plastic injection molding processes to choose from. Based on your project, you can choose from the following three processes:
Even though the names of these primary methods hint on how they operate, it is advisable that one consults with a professional engineer to find out the best process to go with. Each method features unique benefits that can be leveraged to maximize performance and minimize production costs. Making the right process selection for a project ensures the production process yields high-quality, reliable parts.
The right injection molding company will help you determine the volume requirements for the project. Since plastic injection volume shifts over time, it is important to have a professional plastic injection molding manufacturer to work with. A well-reputed plastic injection molding in California will provide specialization in one of these three volume classifications:
Low volume
High volume
Middle volume
There are two types of injection molding resins to choose from: amorphous (plastic cutlery and electronic components) and semi-crystalline (bottles, packaging, pipes and medical implants). Each type of resin is available in affordable, moderate and high-performance solutions. When selecting a plastic resin, you should begin by choosing the family of material that will give you most of the properties you want. The right resin guarantees optimum product performance, so it is important that you consult with experienced plastic injection molders to determine the ideal choice for your project.
Plastic injection molding is cost-effective and gives quality output; however, knowing what to expect from the molder helps you know what to expect. These questions will help you identify the right molder to work with and the right price to pay. If you are looking for the right molding company to work with, Valencia Plastics is here to serve you. Contact us today for more information about our injection molding services.
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