“Accumold is rightly today acknowledged as the world leader when it comes to the manufacture of extraordinarily small plastic parts that require extreme precision — typically measured in microns,” said Paul Runyan, VP of sales and marketing. “The company is adept at the production of small-sized parts with micro features from 5 cm to less than 1 mm, and has specific expertise in insert molding, two-shot molding, and cleanroom molding using an array of materials including PEEK, liquid crystal polymers, and most engineering thermoplastics.”

Further, mPP previously showed promise in sealant film applications but has since been outshined by materials such as Vistamaxx. There is, however, renewed interest in adoption in medical bags, where replacement of random PP copolymer and TPO materials is envisaged. Injection-molded medical device components are another potential outlet for mPP, as well as housewares and semiconductor transport trays.

LyondellBasell metallocene solutions also address concerns about the use of highly regulated substances. With no phthalates or bismethoxyfluorene being used during the production of the product, LyondellBasell provides food packaging manufacturers with an alternative.

The company routinely molds cannulas at volume with outside diameters of 0.035 in. (0.889 mm), inner diameters of 0.027 in. (0.6858 mm), and wall thicknesses measuring 0.004 in.(0.1016 mm). “We have achieved this through attention to material choice, several critical design for manufacturing operations, assembly considerations, maintaining a balanced aspect ratio to avoid challenges associated with flow dynamics, cooling, structural integrity, and importantly through the use of our proprietary micro-molding presses,” explained Runyan. “Micro molding thin-walled cannulas is a game changer for medical device manufacturers, overcoming the labor-intensive, time-consuming, and expensive traditional thin-wall cannula manufacturing processes such as extrusion, tipping, and gluing to a metal hub.”

Coming to market around the same time as its polyethylene partner, metallocene-catalyzed polypropylene is playing a more subdued, yet important, role in niche applications.

Metallocene-catalyzed polypropylene (mPP) was developed around the same time as metallocene-based polyethylene (mPE), but sales of the two materials have been lopsided, with the mPE market perhaps 15 times larger. Nevertheless, mPP suppliers still hold hope that the resin will play a more prominent role in markets where purity and performance are priorities.

Exhibitor Accumold will explain how micro molding thin-walled cannulas reduces labor requirements and cost compared with conventional production methods.

The ISO 13485–certified company is sufficiently large to offer affordable pricing and the capacity and infrastructure to ramp up to full mass-volume manufacturing, he added.

IME South comes to the Charlotte Convention Center in Charlotte, NC, on June 4 to 6, 2024. In addition to more than 300 exhibitors on the show floor, the event features more than 40 educational sessions led by experts in 3D printing, medical technology, packaging, and smart manufacturing. A welcome reception is scheduled at the NASCAR Hall of Fame on June 4. Tickets are available for purchase when you register to attend.

Editor in chief of PlasticsToday since 2015, Norbert Sparrow has more than 30 years of editorial experience in business-to-business media. He studied journalism at the Centre Universitaire d'Etudes du Journalisme in Strasbourg, France, where he earned a master's degree.

Albeit a niche market, several mPP suppliers including Korea’s LG Chem and TotalEnergies have earmarked mPP as having further potential in automotive interior applications on account of its low odor, minimal emissions of volatile organic compounds (VOCs), and fogging characteristics. These attributes are welcome given the increasingly stringent regulation of VOCs in Europe and elsewhere. Previously, Japan Polypropylene also demonstrated the ability of its Welnex metallocene TPO to eliminate weld lines and realize excellent surface appearance in glass-fiber-reinforced automotive interior components.

One standout application for mPP is injection-molded-film food packaging. This segment is another particular focus at supplier LyondellBasell. In an era where consumer safety and sustainability are paramount, the company’s Metocene grades are said to offer low odor, ensuring that taste and aroma of packaged food remain unaffected. This is a significant development for brands looking to maintain the organoleptic qualities of their products while reducing their environmental impact.

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and a proud dachshund owner.

MPP initially found its niche in the spunbond and meltblown nonwoven textile market, especially in the production of hygiene products such as diapers and wipes. It allows finer denier fibers to be produced, meaning not only reduced material usage but also the production of more drapable and softer textiles. In combination with propylene-based elastomers such as Vistamaxx from ExxonMobil Chemical, even softer, higher-loft, drapable nonwoven textiles can be realized.

Vertical integration enables the company to operate as a one-stop partner in the development and manufacture of medical devices and components, added Runyan. “Under one roof, Accumold offers design and material assistance, micro tool fabrication, proprietary micro-molding services, cutting-edge metrology, assembly, and automation, and this facilitates the streamlining of customer’s medical product development process, and the attainment of optimal outcomes in terms of timeliness, cost, and accuracy.”

In addition to its numerous advantages in terms of safety and sustainability, Metocene-based grades also reportedly excel in enhancing the aesthetics of packaging solutions in terms of exceptional clarity and transparency, providing excellent visibility of the contents inside. This feature, often referred to as "shelf visibility," not only allows consumers to see the product they're purchasing but also adds a touch of elegance to the packaging.

The medical device industry demands absolute precision, totally repeatable manufacturing processes, and zero failure rates for products that are frequently used in safety-critical applications, notes Accumold in its announcement.

Furthermore, metallocene solutions can impart a glossy and brilliant finish to the packaging, making it even more appealing on store shelves. This aesthetic appeal serves as a compelling selling point for brands across various industries, aligning with the growing demand for visually pleasing and attractive packaging solutions.

Now that NPE2024 is history, there are some admittedly smaller but still worthy trade shows on the horizon for sourcing suppliers of plastics processing services. One that you may want to consider attending is Plastec South, co-located with Medical Design & Manufacturing (MD&M) alongside packaging, automation, design and manufacturing, and Powder Bulk Solids trade shows under the IME South umbrella in Charlotte, NC. In particular, a pioneer of medical micro molding will be exhibiting at the event in June.

LyondellBasell reports that its Metocene metallocene solutions are sparking a renewed interest in the textile industry, not only because of their downgaging capability but also on account of their low odor characteristics, a feature that is considered paramount in more-comfortable and discreet hygiene products.

In booth 1911, Accumold will be showcasing some of the tiny titans it has produced to exacting specifications for medical device OEMs over its nearly 40-year history. A highlight are thin-walled cannulas that the company can now micro injection mold at volume.