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MedTech Outlook | Wednesday, September 28, 2022
Injection molding is versatile enough to accommodate many materials, from expensive engineering resins to inexpensive common plastics.
FREMONT, CA: Although injection molding is not the only process used to manufacture plastics, it is one of the most cost-effective options for big-volume production. Although it seems like an expensive investment, the cost of an injection mold can be amortized or stretched across many parts, resulting in a cheap cost-per-part. For instance, if a mold that costs $10,000 is amortized across 100,000 pieces, the tooling cost is only ten cents for each item.
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Injection molding allows for the use of a wide variety of materials, from high-performance engineering resins to low-cost common plastics. Polymers are chosen for their special properties by designers and engineers. These polymers can range from thermoplastics that melt at high temperatures to thermosets that do not melt. Plastics are available in various grades, including medical-grade plastics, distinguished by their use of components whose biocompatibility has been established via extensive testing. In addition, injection molding can make parts of various geometries and dimensions.
Injection molding allows for precise tolerances, which are essential in the medical field. It is perhaps the most crucial benefit. Injection-molded components are frequently used as components within larger assemblies. Tolerance stack analysis is a technique utilized in medical device design to guarantee that the individual components are assembled in the proper order. If misalignments take place, a redesigned component might be necessary. Rework during production not only adds to costs but also has the potential to delay the introduction of new products (NPI).
Even though injection molding offers a number of benefits, it is not always the best option for a plastics project. Because technology does not require tooling, for instance, three-dimensional printing can be more cost-effective even when producing items in low amounts, such as prototypes. Injection molding offers a much more comprehensive selection of specialist polymers than 3D printing, and the materials used in 3D printing don't have the same end-use qualities. 3D printing offers a wider selection of general polymers.
A certificate of analysis (COA) or certificate of conformance (COC) issued by an independent testing lab may be necessary for the plastics used in medical injection molding. This distinction is crucial because some manufacturers claim to use USP Class VI compliant ingredients but cannot guarantee the compliance of the final product, especially if they substitute ingredients.
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