Turn up the volume
UK silicones group Primasil (stand 61A) will be discussing solutions for high volume work at this year’s Med-Tech Innovation Expo.
Traditional moulding techniques remain commonplace for components with design attributes on more than one dimension. But tooling can be expensive, and for non-automated processes, prices may be relatively high. That’s not all - traditional machinery may not be able to satisfy very high volume requirements.
This can be problematic. While custom manufacturing processes may be developed for some parts, high development and prototyping costs make this prohibitive in many cases.
Primasil says that automated punching may provide an answer. Components less than 3mm thick may be cut from silicone rubber sheet with a shaped steel strip. Not only are the tooling costs lower, but the automated process means the labour required is minimal. This, Primasil says, results in much lower part prices than when using traditional manufacturing techniques. Quality can also be automated, with inline cameras taking the place of manual inspection.
The Saint tourniquet is an example of this. Fabric tourniquets had been falling in popularity due to infection risk, so elastomeric alternatives were introduced. But these were over-engineered, and too expensive for the single-use demands of the marketplace.
The Saint uses a patented locking technology which allows single-handed use. It also makes possible production using automated punching. With a much lower part price, these tourniquets are now reportedly being adopted in clinics around the world.
The group points out that punching isn’t suitable for all components. The product must be flat with no detail on the upper and lower surface. Also, very soft materials will deform when cutting, so the edges may not be perfect. Nonetheless, for certain applications, punching may bring high volume capabilities with rapid ramp up.
Straps, gaskets, seals, washers, and self-adhesive backed sponge are just some of the components Primasil currently produces with automated punching machines. Many of these are then packaged in an ISO certified cleanroom, before being sent to medical device manufacturers or end customers across the globe.
As a silicone rubber supplier with automated punching capability, Primasil reports that it is experiencing increasing demand for punched products as medical device OEMs are facing increase price pressure.