Polyetheretherketone (PEEK) is a high-quality thermoplastic known for its exceptional resistance to harsh environments, including radiation, high temperatures, chemicals, and wear and tear conditions. PEEK is perfect for creating medical and surgical implants and offers impeccable dimensional stability, even after being exposed to stress.

Are you searching for high-quality, precise mold manufacturing solutions for your medical devices? At Remington Medical, we offer excellent contract manufacturing services that ensure consistent, high-volume production.

A general rule of thumb is 2-8 tons per square inch.  For example, a 10” x 10” part (100 square inches x 2 tons/sq. in.) = 200 tons.  The larger the part the more clamp force is required to hold the two halves of the mold together during the injection process.  There are several factors that influence the amount of clamping force required including wall thickness, geometry, gating of part, viscosity of resin and temperature of injection mold.

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As plastic melt is injected into the steel cavity of the mold, heat is transferred into the steel and the plastic begins to cool.  If the resin cools (“freezes off”) before reaching end of fill for the cavity, you will have a “short shot”.  Increasing the temperature of the mold will help the plastic material flow better and require less pressure and thereby less clamping force to hold the mold closed during fill.

Injection molding is not only automated, but it also significantly reduces labor costs. With computer-controlled precision, each part is efficiently produced, resulting in lower costs per unit.

The more tortuous the path and further the distance the plastic melt travels, the greater volume of melt is being pushed and greater transfer of heat from the melt flow to the steel cooling the plastic.  The additional material and resistance to flow as travel distance increases requires additional injection pressure and clamp tonnage.

Did you know that injection molding is revolutionizing the medical device industry? This innovative manufacturing process ensures the creation of high-quality, precise, and cost-effective medical devices.

Polyethylene (PE) is a versatile, durable medical-grade plastic polymer composed of thousands of ethylene polymers, giving it impressive tensile strength and rigidity. PE is also highly compatible with biological tissues and can withstand harsh environmental conditions, including sterilization. Thanks to these properties, PE is widely used in the medical field for manufacturing joint prostheses, connectors, tubing, pharmaceutical containers, and more.

With additive manufacturing, medical professionals can now rely on high-quality injection parts that meet the strictest industry standards. Whether it’s intricate surgical tools or complex implantable devices, injection molding for medical devices ensures that every component is flawlessly fabricated for optimal performance. This medical parts manufacturing process is common to develop a wide range of components, devices, and parts, such as:

Thicker wall sections provide more volume for the plastic melt to flow.  As plastic melt travels to the end of the mold cavity, the steel is removing heat.  Thicker wall sections provide insulation for the melt and allow it to travel further with less pressure.  Similarly, the thinner the wall the faster heat is transferred from the plastic melt and more pressure is required to push the melt flow into thin sections.

Overmolding is an advanced technique that involves molding one or two components over an existing structure, resulting in a strong and durable grip. This two-step process, also known as two-shot molding, may have a longer production cycle, but the benefits are well worth it. With overmolding, manufacturers can create ergonomic handles to improve the comfort of everyday devices, which adds value and functionality to a wide range of items.

In this article, we have not listed every factor, but these represent the main considerations for selecting the proper injection molding machine clamp tonnage.  Texas Injection Molding is one of the largest custom injection molding companies in Texas and has made the strategic decision to position our company to offer a broad range of capabilities at a single location.   Texas Injection Molding works closely with our customers during initial stages of product development to ensure part performance and efficient manufacturing. We are certified to the standards of ISO 9001-2015 and have a full-service tool and die shop to complete routine maintenance, engineering changes and repairs in a cost-effective and timely manner.  In addition to our fleet of small to medium tonnage machines, we have several large tonnage machines and have planned our building, utilities, material handling and lifting capabilities to meet these broad manufacturing requirements.

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Medical injection molding ensures that the produced components meet all necessary regulatory requirements set by the FDA.

Plastic injection molding involves melting plastic polymers at high temperatures to create sterile and contaminant-free medical equipment. By reshaping the plastics in aluminum or steel molds, manufacturers can produce precise and customized medical devices that meet the highest standards of hygiene.

Polystyrene (PS) is a high-quality engineering-grade plastic that’s not as flexible as others, but it has exceptional mechanical properties and is compatible with body tissues. Polystyrene offers excellent dimensional stability, making it ideal for creating critical medical components like petri dishes, culture trays, and diagnostic parts.

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The medical injection molding process involves melting medical-grade plastics and molding them into the desired shape of medical devices. This process creates strong, durable equipment with impeccable surface finishes and precise measurements.

Injection molding guarantees tight tolerances and dimensional accuracy, which are crucial in the medical field. With injection molding, even the smallest deviations can be avoided, reducing the risk to patients.

Similar to overmolding, the insert molding technique involves molding a secondary component over an existing part, or the insert. What sets insert molding apart is that it is a single process and can be used with various materials, such as plastics, metals, or alloys.

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Silicone, a unique chemically inert compound similar to synthetic rubber, offers exceptional mechanical properties and compatibility with biological tissues. With its exceptional flexibility, silicone is the go-to medical-grade plastic polymer for manufacturing a wide range of products and devices, such as catheters, connectors, and tubing.

There are many different grades of plastic resin.  Plastic resins are generally specified by the physical, environmental and chemical resistance properties required of the finished parts.  Each grade of resin has an ideal processing temperature range without degrading the properties during manufacturing.  Each different grade of resin will have different rate at which the plastic melt flows.  The Melt Flow Index (MFI) is a measure of the ease of flow of the melt of a thermoplastic polymer.  It is defined as the mass of polymer, in grams, flowing in ten minutes through a capillary of a specific diameter and length by a pressure applied via prescribed alternative gravimetric weights for alternative prescribed temperatures.  Thermoplastic resin manufacturers can formulate the thermoplastic resin to have a range of MFI within a specific grade. The higher the MFI, the easier the melt flows.  The higher the MFI the less injection pressure is required to fill the cavity and less clamp tonnage required by the molding machine.

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Polypropylene (PP) is a highly effective plastic polymer commonly used in medical injection molding. With its exceptional strength and resistance to cracking, radiation, impact, temperature, wear, and tear, it’s no surprise that it is a top choice in the healthcare industry. From life-saving syringes and connectors to essential knee and hip replacements, PP is the preferred material for producing critical components in healthcare.

A large tonnage injection molding machine requires a large amount of resources.  The footprint of a large tonnage machine is approximately 40’ x 8’ x 8’.  The capital cost of a large machine can start at $250,000 and can exceed $1MM.  The injection molds that are processed in these machines exceed 10,000# and require special lifting equipment.  The facility foundations must be suitable for machines exceeding 100,000 lbs.  The utilities required to operate a large machine are great and are expensive to bring to the building.  Large tonnage machines typically run larger parts.  Handling and storing large quantities of large parts requires considerable space for staging, packaging and storing parts.  As a result of these considerations, there are fewer companies that choose to offer machines >500 tons.

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Our injection mold manufacturing process is ideal for products and plastic parts that require large-scale production. With scalable injection molding machines, we can easily adjust to meet your needs with consistent, high-quality production every step of the way. Contact us today to learn more about injection molding for medical devices.

During the injection molding process hydraulic cylinders push the screw forward injecting melted plastic resin into the cavity of the mold at extremely high pressures.  Pressures exceeding 20,000 p.s.i. during injection push the two halves of the mold apart.  Injection molding machines are rated by “clamping force” in tonnage.  The tonnage of force clamping the two halves of the mold together.  The larger the surface area of the molded part, the greater the tonnage is required.  Generally “large tonnage” machines are machines rated with 500 or more tons of clamping force.

Injection pressure is a measure of pounds per square inch (PSI) required to inject the melted plastic resin to displace the air and fill the cavity under adequate pressure for form a quality part.  The clamp on an injection molding machine “clamps” the two halves of the mold together during injection, packing and cooling process of manufacturing a plastic part.  The greater the injection pressure pushing plastic melt into the cavities the greater the clamp force required to hold the mold together.

When it comes to medical products, such as syringes, gloves, and masks, the ability to produce high volumes with consistency is crucial. This is where injection molding excels. With this technique, once the mold is created, thousands of identical parts can be produced without the need for maintenance.

Polycarbonate (PC) is transparent and has excellent mechanical properties. It’s tough, flexible, and resistant to abrasion, breakage, and temperature. Polycarbonate is also highly compatible with bodily tissues, making it ideal for manufacturing various medical equipment, from clear masks to protective gear and oxygenators.

Liquid silicone injection molding involves heating silicone to a liquid state and then molding it into various shapes, making it a versatile solution for developing medical products. Silicone, a plastic polymer, is specifically designed to meet the needs of the medical industry. However, it’s important to note that silicone molds may not be as durable as aluminum or steel molds, making this technique more suitable for small quantities and initial prototyping stages.