AJP. Accumold's innovation significantly improves the functionality and reliability of wearable diabetes devices by reducing overall costs and minimising potential issues associated with traditional production methods. By eliminating the need for glued components, which can come loose and compromise the device's integrity, the new micromoulding process ensures a more secure and durable assembly. This advancement leads to fewer failures in the field, enhancing the user experience and trust in the device's reliability.

The company's extensive experience with a wide range of products has given it a deep understanding of the intricacies involved in micromoulding. This knowledge ensures that we can consistently produce high-quality, reliable components that meet stringent industry standards. The ability to mould such fine and consistent structures sets Accumold apart, allowing the company to meet the specific needs of clients and advance the capabilities of wearable medical devices. This innovative process not only improves the performance and reliability of thin-walled cannulas but also demonstrates Accumold's leadership in the field of micromoulding technology.

This study was also supported by companies including iQTemp, Deutsche Edelstahlwerke, 3D Laser BW, and Siemens NX, as well as institutes, such as Fraunhofer ILT and ACAM.

AddUp established its AM Tooling Competence Centre in Aachen, in partnership with WBA, in early 2023. This facility, which also serves as AddUp’s German subsidiary, gives tooling manufacturers access to AddUp’s Additive Manufacturing machines. Users can also submit application cases for evaluation and study of all aspects of their project, from the design when applied to PBF-LB, to profitability analysis and study of series production.

Additionally, Accumold's capability to produce high volumes, in the tens of millions, with consistent quality means that manufacturers can rely on a steady supply of uniform components. This consistency is crucial for the final device's performance, as it ensures that each unit operates as intended, reducing variability and increasing the overall reliability of wearable diabetes devices. The ability to maintain such high standards at scale makes these devices more accessible and dependable for users managing diabetes.

AJP. Thin-walled cannulas are crucial in modern wearable diabetes devices due to their ability to deliver insulin or other medications with minimal discomfort and high precision. These devices require components that are both small and efficient to ensure patient compliance and comfort. Thin-walled cannulas allow for a less invasive experience, reducing pain and irritation during insertion and while worn, making them ideal for continuous or frequent use. Their micro-sized design also helps maintain the compactness of wearable devices, which is essential for user convenience and discretion.

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

AJP. We were inspired to develop a new method for micromoulding thin-walled cannulas when a client approached us with a specific challenge — moulding a product with an exceptionally thin wall. Recognising that this request aligned well with our core competencies, the Accumold team saw an opportunity to leverage our expertise in precision moulding. This realisation prompted a collaborative effort to explore innovative solutions, drawing on our extensive experience and advanced capabilities in micromoulding to meet the client's unique requirements.

Furthermore, the assurance of high-quality, reliable components is crucial for medical devices used in diabetes management. Patients rely on these devices for their daily health and well-being, making reliability and precision paramount. Accumold's innovation addresses these needs by ensuring that every component meets rigorous standards, thereby enhancing the overall trust and effectiveness of wearable diabetes devices. This not only helps manufacturers stay competitive in a crowded market but also ultimately benefits patients by providing them with more reliable and affordable medical solutions.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

AJP. Accumold's new micromoulding method offers significant advantages in terms of production efficiency, cost-effectiveness, and scalability. By eliminating secondary processes and multistep procedures — which often lead to rework or failed assemblies — the method streamlines production. This reduction in steps not only enhances efficiency but also lowers the likelihood of defects, resulting in a more reliable and consistent product. The streamlined approach ensures that each component meets the stringent quality standards required for medical devices, thereby reducing overall production costs.

AddUp SAS, headquartered in Cébazat, France, has partnered with WBA Aachener Werkzeugbau Akademie (WBA), in Aachen, Germany, to demonstrate the advantages of metal Additive Manufacturing for the mould making industry. After launching a Tooling Study in January 2023, the team found six tool-making companies that each identified existing moulds to be tested. AddUp and WBA have now produced the first prototypes of these injection moulds, all with optimised internal cooling channels.

AJP. Accumold's new micromoulding process for thin-walled cannulas is unique primarily because it utilises moulding rather than extrusion. This approach allows for greater precision and control over the final product's dimensions and quality. Our expertise, honed over 40 years and more than 7000 projects, enables us to achieve micro tolerances and thicknesses as fine as .0006 inches or less. This level of precision is critical for medical devices, where even the smallest deviations can impact functionality and patient safety.

AJP. Accumold maintains the high quality and precision required for thin-walled cannulas through a dedicated and highly skilled quality team. This team acts as an extension of the client's project team during the design process, ensuring that all specifications are met at each phase of the project and into full-scale production. By integrating quality assurance into every step of the design and manufacturing process, we ensure that the final products adhere to the strict tolerances and standards necessary for medical devices.

Our ability to shape products to exact specifications played a pivotal role in this development. Accumold's design team worked closely with the client to ensure the right gating and injection strategies were employed, guaranteeing a high-quality end product. By focusing on precision and customisation, Accumold was able to overcome the technical challenges associated with moulding thin-walled cannulas, ultimately advancing the field of wearable diabetes devices and demonstrating our commitment to meeting complex client needs with innovative solutions.

Accumold's commitment to quality is reinforced by its ISO 13485 certification, which underscores our adherence to international standards for medical device manufacturing. This certification ensures that the company follows rigorous guidelines and best practices for quality management systems, enhancing our ability to produce reliable and precise components consistently. By combining our expert quality team with adherence to ISO standards, Accumold can deliver thin-walled cannulas that meet the highest levels of precision and reliability, crucial for the efficacy and safety of medical devices.

AJP. Traditional production processes for thin-walled cannulas often face significant drawbacks, including high fallout rates and the need for multiple complex steps. The tipping process, essential for shaping the tips of traditionally made cannulas, frequently results in inconsistent quality and increased wastage. In addition, traditional methods require fluing, a process of attaching plastic or metal hubs, which can further complicate production and add to the overall costs. These steps not only increase the risk of defects but also drive up expenses, particularly when manufacturing in high volumes, making the process inefficient and costly.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

For the project, post-processing was completed by the tooling company itself or by the WBA. Each of these ready-to-use moulds is now being sampled on the respective tooling company’s production lines, and the comparative data will be provided to WBA. The final results of the Tooling Study will be presented and published at the WBA’s General Assembly in late 2023.

A.J. Pruitt, technology manager at Accumold discusses the impact of the company’s successful drive towards the efficient micromoulding of previously extruded thin walled cannulas, and what this means for industry.

AddUp plans to launch a follow-up Tooling Study this autumn, and is inviting any tool makers interested to get in touch.

AJP. Accumold's future plans for innovation in micromoulding are centred around challenging traditional manufacturing methods and exploring the potential of moulding to enhance product quality, reduce costs, and increase production volumes. The success of our thin-walled cannula project has demonstrated that the old ways of manual or automated assembly are not always the most efficient or effective. By leveraging advanced moulding techniques, Accumold aims to provide solutions that simplify production processes, improve product integrity, and scale up manufacturing capabilities. This approach is being extended to various projects involving overmoulding and lead frame moulding, where we have already achieved significant cost and time savings for our customers.

Reach a truly international audience that includes component manufacturers, end-users, industry suppliers, analysts, researchers and more.

Once selected, AddUp and its partners evaluated each injection mould to determine how it could be optimised with Additive Manufacturing. Each part was then redesigned for AM, optimised for conformal cooling, and manufactured on AddUp’s 4-laser FormUp 350 Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing machine at AddUp’s AM Tooling Competence Centre in Aachen.

AddUp explained that the choice of material is critical for tool makers, as moulds must meet high requirements, especially in terms of corrosion resistance, heat conductivity, and fatigue. Leveraging its twenty years of experience in AM, AddUp used Maraging 300, a material successfully used in series production by Michelin to manufacture over a million tyre mould sipes per year. In addition to Maraging 300, AddUp recently announced build parameters for AISI 420, a corrosion-resistant tool steel also known as 1.2083 in the German standard. It is expected that this new material will enable tooling manufacturers produce even more complex and efficient moulds.

Thin-walled cannulas also enhance the accuracy and reliability of drug delivery. The precision in their manufacturing ensures consistent lumen size, which is vital for accurate dosing and maintaining the effectiveness of the treatment. This reliability is particularly important in managing chronic conditions like diabetes, where precise medication administration directly impacts health outcomes. The innovation in micromoulding techniques for producing these cannulas, as developed by Accumold, addresses the limitations of traditional extrusion processes (which often require secondary processes such as tipping, flaring, and even gluing which adds to costs and chances of failure), leading to improved performance and broader adoption of advanced wearable diabetes management solutions.

Accumold's apability to scale quickly and produce very high volumes is also a key advantage. Our expertise allows us to efficiently ramp up production to meet large demands, making it possible to produce tens of millions of components without compromising on quality. This scalability ensures that we can meet the needs of large-scale manufacturers while maintaining cost-effectiveness. The ability to produce high volumes consistently and efficiently makes Accumold's micromoulding method a superior choice for industries requiring precise and reliable components, such as wearable diabetes devices.

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

Accumold's new method addresses these issues by streamlining the production process and enhancing precision. By utilising advanced micromoulding techniques, we eliminate the need for the tipping process and reduce the reliance on fluing. This results in a more consistent product with significantly lower fallout rates. The integrated approach ensures that each step is optimised for efficiency, reducing the number of stages and associated costs. This innovation not only improves the quality and reliability of thin-walled cannulas but also makes high-volume production more feasible and economical.

Non-medical applications could also benefit from this innovation. Industries such as biotechnology, pharmaceuticals, and even aerospace require highly precise, small-scale components. For instance, in biotechnology, these cannulas could be used in microfluidic devices for lab-on-a-chip applications, enabling precise control of fluids at a microscopic level. In the pharmaceutical industry, they could facilitate the development of advanced drug delivery systems, enhancing the effectiveness of new medications. The aerospace industry might use them in systems requiring the precise management of fluids or gases in confined spaces. The versatility and precision of Accumold's micromoulding technology make it applicable to a diverse array of fields beyond medical devices.

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

The companies selected for the Tooling Study were Pöppelmann, Siebenwurst, Harting, Zahoransky, GIRA, and Framas. They were given the opportunity to test the introduction of Additive Manufacturing into their workflow, and specifically implement the technical and economic advantages that AM technology brings to their injection moulds.

This recent development aligns with Accumold's long-term vision of being at the forefront of micromoulding innovation. By continuously pushing the boundaries of what is possible with moulding technology, we strive to offer solutions that meet the evolving needs of our clients across various industries. The focus on reducing manual intervention and enhancing automation reflects Accumold’s commitment to optimising production processes and delivering high-quality components at competitive prices. As the company expands its expertise and capabilities, Accumold is poised to set new standards in the micromoulding industry, ensuring we remain a trusted partner for companies seeking innovative and efficient manufacturing solutions.

AJP. The innovation in micromoulding thin-walled cannulas is poised to significantly impact the medical device market, particularly for diabetes management. As the market becomes increasingly saturated, there is a pressing need for cost-effective solutions that do not compromise on quality. Accumold's advanced moulding techniques offer a way to reduce production costs while maintaining high standards of quality and reliability. This ability to provide high volumes of consistently superior components allows manufacturers to meet the growing demands of their patients efficiently.

AJP. Beyond wearable diabetes devices, the ability to micromould thin-walled cannulas holds significant potential for a wide range of medical and non-medical applications. As the wearable device market grows, there is an increasing demand for smaller, more precise components that can deliver medications or other therapeutic agents efficiently. Any device requiring precise delivery, such as insulin pumps, pain management systems, and drug delivery implants, can benefit from these advanced cannulas. Their small size and high precision make them ideal for minimally invasive procedures, improving patient comfort and treatment efficacy.

Traditionally, manufacturers using injection moulding must contend with certain constraints that are inherent to the moulding process. Specifically, the mould’s performance is directly related to its ability to cool the injected parts. However, AM technology can be used to create complex cooling channels that are positioned as close as possible to the mould walls. By adapting the shape of these channels to cool the surface of the part more homogeneously, manufacturers can improve the quality of their products and experience higher productivity, as well as reduced cooling and cycle times.