If you missed Pt.1 – The Rise of Miniaturization, check out our case study here for an overview. The write-up below builds on the insights from the case study.
BACKGROUND
The medical device industry continues to undergo a significant transformation driven by the trend of miniaturization. As the next generation of medical devices become more compact, the demand for smaller, more intricate components continues to rise. This trend pushes the limits of conventional tooling, engineering and injection molding. Recognizing the challenges associated with manufacturing these precise components, a medical customer approached us seeking a partner with the expertise and advanced technology needed for this highly intricate tooling project.
SCOPE
This project aligned perfectly with Matrix Tool’s technical capabilities, expertise, and advanced tooling and molding equipment. Given the complexities found in both micro tooling and micro injection molding, this project needed advanced engineering solutions and innovative tooling designs to achieve successful production of this micro component. Initially, the customer requested a complex 16-cavity solution with a hot runner and an aggressive target cycle time. Our engineering team identified inefficiencies and multiple areas for improvement. We proposed a unique, alternative 8-cavity all-cold runner solution that increased throughput while significantly reducing tooling complexity, cost, and risk—ultimately exceeding the original 16-cavity output. This innovative approach was initially met with skepticism as it challenged the traditional belief that increasing cavity levels automatically boosts output and lowers piece prices. However, our innovative solution reduced complexity and headaches while requiring zero conditioning loops, demonstrating the effectiveness and soundness of the approach.
CHALLENGE
This component posed several significant challenges due to the small sizes, features and lightweight nature. The intricate micro-featured geometry of the part required complex tooling with multiple inserts measuring just seven thousandths (0.007”) of an inch wide with zero draft and featuring a straight bypass shut-off in order to achieve the desired shape and product features. Additionally, precise alignment and a high-quality steel finish were essential to ensure optimal performance. Each part weighed a mere 0.024 grams. Due to their small size, these components demanded precise handling and molding techniques to uphold quality and consistency. The use of a 30% Glass Filled Liquid Crystal Polymer (LCP) resin added another layer of complexity due to its challenging processing characteristics and the necessity for precise tolerances.
Part Size: 4.18mm x 4.61mm. The component shown above is placed on an iPhone keyboard key for scale.
CONCLUSION
By leveraging advanced technologies, state-of-the-art equipment and innovative solutions, we successfully navigated the miniaturization challenges of this project, achieving substantial improvements in efficiency, cost savings, and part quality. Our commitment to reducing tooling complexity, minimizing material waste, and decreasing variability and cycle times—while simultaneously improving consistency and overall part quality—demonstrates our dedication to pushing the boundaries of what is possible in tooling and molding. Our customer’s total lifecycle costs were significantly reduced without compromising output, while also increasing margins. We are well-equipped to support customers in meeting the dynamic demands of their markets—so do not hesitate to reach out to Matrix for assistance with your most challenging tooling and molding projects.
More than 10% of Matrix Tool, Inc’s staff are degreed plastics engineers, providing the necessary expertise and resources to guide your most complex tooling and molding projects from concept through production.
CONTACT US
Why continue to use the same approach when improvements through our unique, engineering-driven full-service offerings are a phone call away?
With over 50 years of experience as a premier manufacturing partner and strategic supplier, Matrix Tool, Inc. is ready to assist with your most demanding manufacturing needs. Reach out today to discover how our unique full-service offerings can enhance your projects. For high-precision tooling or advanced injection molding inquiries, fill out our Contact Us form, call us at 814-474-5531, or email us at [email protected].
