While incorporating various techniques of rapid prototyping and precision engineering, MPP Corp manufactured a comprehensive medical prototype package within an ambitious four-week timeframe. This project involved the production of 500 parts for each mold, with a focus on incorporating advanced technical features to meet the stringent demands of medical applications.
The prototype package included:
- Two unscrewing mechanisms
- One two-shot over-molded part
- Four conventional molds with hand loads
Choosing the Right Materials
Central to the success of the project was MPP Corp's strategic choice of materials. All seven tools were meticulously crafted using P-20 mud units. P20 Mold Steel is a versatile, low-alloy tool steel with good toughness at moderate strength levels, making it ideal for demanding medical applications.
Innovative Unscrewing Mechanisms
Among the standout features of the project were the two molds equipped with unscrewing mechanisms. These mechanisms were specifically tailored to create a flawless external thread within the finalized components, particularly the luer thread/fitting. Luer fittings are used to create a secure, leak-free connection between different components, such as syringes and catheters. The fitting comprises a male and female connector that securely screw together. The male connector features a tapered end that snugly fits into the female connector, while the female connector incorporates a threaded sleeve that screws onto the male end.
Two-Shot Over-Molding Expertise
The prototype package additionally featured a two-shot over-molded part. This resulted in a final product consisting of two distinct materials, with one material over-molded onto the other. The process is commonly used to enhance a product's functionality, aesthetics, or ergonomic features. Two-shot plastic injection molding eliminates post-molding assembly, reduces the number of plastic molds needed, and reduces part handling by operators.
Conventional Molds
The prototype package featured four conventional molds with hand loads. Hand loads present a flexible method in injection molding, enabling experimentation with diverse designs without requiring extensive mold modifications. This adaptability makes hand loads especially valuable in the context of prototyping. These molds, crafted with precision machining and tooling techniques, played a vital role in shaping components that complemented and augmented the overall functionality of the medical tools.
Collaboration for Success
One of the project's key highlights was MPP Corp's collaborative approach, actively engaging with the customer on design for manufacturing (DFM). By working on DFM, MPP Corp was able to identify and address potential issues early on, ensuring the parts could be molded efficiently and effectively. This collaborative approach not only saved time but also helped optimize the final product for manufacturability, potentially reducing costs and lead times in future production.
MPP Corp is Committed to Your Success
MPP Corp's completion of the 7-tool medical prototype package in four weeks is a testament to our technical expertise, commitment to quality, and unparalleled ability to deliver custom solutions under tight deadlines. For businesses seeking reliable and efficient solutions in plastic injection molding, we can be your trusted partner. Contact MPP Corp today to discuss your project needs.
