Four different mold samples were manufactured including the original part designed by an experienced engineer, the second based on generative design, another based on generative design but with looser shape restrictions and finally, a design similar to the first with additional water channels. Products from each mold were then measured to assess performance and the results showed there was little difference in performance between the generatively designed cooling channels compared to the engineer’s design.

In addition to the process parameters controlled by the machine, the thermal processes in the injection mould are of great importance for component quality. In medical technology, solutions that can measure and evaluate temperatures and water flow per connection on the mould are becoming increasingly popular. Netstal relies here on the system from market leader Mouldflo, which uses specially developed measuring manifolds to ensure seamless monitoring of the cooling water supply. Based on the vortex principle, the flow rates of each individual cooling circuit are recorded and monitored using highly sensitive sensors. In addition, the water temperature in the flow and return of each cooling circuit is measured. This information provides a comprehensive overall picture of the thermal processes in the mould, which must remain within the validated process window at all times.

At Fakuma, Netstal will be producing 10 ml syringe barrels with Luer-Lock adapters made of COC using an all-electric Elion MED with a clamping force of 1750 kN.

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During the injection moulding process, a lot of characteristic data is generated that provides information about the production quality. A large number of process parameters are available in the control system, which can be evaluated, displayed and monitored. The main focus is on the shaping phase. The quality of the moulded part is largely determined during this injection and pushing forward phase. Continuous monitoring of all relevant parameters ensures compliance with the validated tolerance limits. Histograms are used to detect a possible deviation trend at an early stage and issue a warning.

The SKA handling system removes the finished syringes and places them on a conveyor belt. The system communicates with the machine via the Euromap 77 interface and provides additional, quality-relevant process indicators. A thermal imaging camera is used to measure the temperature around the Luer lock adapter of the syringes. The aggregated data from the entire injection moulding process is assigned a unique identifier. Each data set can be traced with a displayed QR code.

Manufacturing processes in medical technology are usually validated and must be kept within the specified tolerance limits. Netstal deliberately avoids software-based adaptation of setpoint specifications, as this can lead to the validated process window being exceeded or undershot. Netstal's solution is called Responsive Filling Control (RFC) and is based on a force-dependent pressure changeover. The technology works with highly accurate and dynamic sensor technology, which is developed and produced exclusively for Netstal. The integrated force control offers conditions for high-precision process control, as it is independent of the material properties and ensures a constant part weight within the tightest tolerances.

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The part weight is 7.8 g and the cycle time is around 20 seconds. Netstal processes a material from Topas through a precision mould with 8 cavities from Fostag. The seamless monitoring of the thermal processes in the mould is carried out using technology from Mouldflo. Material preparation and feeding is ensured by a system from motan colortronic. HB-Therm provides the latest generation of Thermo 6 temperature control units. System partner SKA is providing the fully automatic handling system consisting of high-speed side removal, parts depositing and an integrated thermal imaging camera for recording the demoulding temperature in the area of the Luer-Lock connection. Another integral part of the automation is the complete recording of process and quality parameters and their aggregation to a unique identifier using a QR code. The injection moulding machine is also connected to the MES from digital partner bfa solutions via OPC-UA / Euromap 77.

Given that creating advanced cooling systems is challenging and time-consuming, Uemoto says he hopes this project will lead to more automated solutions that streamline that process, speed up the workflow, and afford engineers more freedom: “If this becomes a part of a packaged software in the near future, it could lead to a solution for speeding up tasks and allow us to develop programs focusing more on temperature control. That should benefit a wide range of users and applications.” You can find more information HERE.

The left was generatively designed with its shape constrained to a designer’s initial shape; The right was generatively designed with its shape constrained only by the initial shape of the outer shell | Credits: Life Solutions Company, Panasonic Corporation.

Seiichi Uemoto, an analyst at Panasonic’s Life Solutions Company, initiated using generative design to deliver new designs that otherwise would have been impossible | Image via Autodesk

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Generative design is a technique that delivers optimized design outcomes based on goals and constraints. Seiichi Uemoto, an analyst at Panasonic’s Life Solutions Company Manufacturing Engineering Center, initiated using generative design to deliver new designs that otherwise would have been impossible. “I thought that with the right settings in place, I could use generative design to automatically create mold-cooling channels,” he explains. The main difference with topology optimization is that it produces “only one solution from the conditions provided to the system. It is difficult to produce something with smooth contours from the generated result. But it became apparent to me that generative design would inherently result in smoother shapes,” he adds.

Therefore, Panasonic Corporation’s Life Solutions Company is betting on a new hybrid manufacturing method that incorporates 3D printing, milling and generative design. Using the LUMEX Avance-25, it was possible to create a conformal-cooling system (which lays out the cooling channels conforming to the shape of the products). The result is a reduction in cooling times by 20% compared to conventional methods, where channels are drilled straight through the mold.

Even though additive manufacturing is moving beyond being a rapid prototyping technology, injection molding is still the most efficient way to mass produce plastics parts. Injection molding is therefore essential for mass-production of plastic parts with complex shapes. In order to create higher quality products at lower costs, it is important to develop advanced cooling systems for melted materials. Panasonic Corporation’s Life Solutions Company, in collaboration with Autodesk, has explored how automating the design of mold cooling channels could help this process.

Therefore, Panasonic worked with Autodesk to apply generative design to the mold cooling water channels for a small, complex, mass-produced fan blade used in duct ventilation systems. Constraints and desired conditions were input into the software, which proposed numerous iterations until just the key components remained. Uemoto explains that he was surprised by the unique behaviour of the resulting water channel layout. “I was really impressed by the fully formed models that were being automatically generated,” he comments.

The choice of injection moulding machine is an essential prerequisite for permanently assured production quality. With its robust construction designed for maximum reliability, the all-electric Elion MED 1750 offers the ideal prerequisites for unique precision, reproducibility and purity in the medical production environment. The enormous control accuracy is ensured by high-performance mechanics, high-precision measurement technology and sophisticated control technology. The latest Axos 9 control generation also ensures efficient control in the injection moulding process with a sampling rate of 2 kHz. The guided Smart Operation button control ensures smooth operating processes in the production environment and high production efficiency.