Medical and technology moulding
6 February 2023
Increasing demand for injection moulding to create the highest quality products across the medical and technology fields has driven the change at Tex Plastics Barnstaple site.
DFM, Prototyping and injection moulding process
Tex Plastics has always been focused on building long-term relationships with our customers. This is best achieved by considering the journey from concept design through to manufacturing and logistics at the very start of a project. Working as one team with the client’s product designers to develop the best possible product within the given price point. It doesn't matter whether it's the smallest of widgets or large-scale, complex assembly - our approach is focused on the end requirement, and working to deliver a tailored manufacturing process to meet our customers’ exact needs.
Understanding the end application drives better design for manufacture
Most medical and technology moulding is to exacting specifications to deliver a solution which meets very complex needs. Whether it's standard, white room or clean room moulding, it starts with interrogating the design to explore what could enhance performance, influence the aesthetic quality and make the manufacturing process more efficient.
Here's an overview of our process
We understand medical and technology moulding is still largely a cost-driven business. Therefore, cost savings and labour-reducing applications are always in focus throughout the process. We strive to be a ‘one-stop shop’ by providing decorative, assembly, packaging, and distribution services - all of which is designed into the manufacturing plan in response to the initial brief.
> Briefing
Understanding that technological breakthroughs and innovations often require more complex injection moulding techniques and solutions is where we start. Our job is to understand the projects expectations, its operational environment, quality requirements and durability needs. At the briefing stage we need to gain a clear understanding of the projects redlines, 'nice to haves' to enable us to provide a solid commercial proposal with realistic expectation management.
> Collaborative DFM Process
Working as a single collaborative team, we work directly with your subject matter experts and product designers. Our project teams are cross functional and comprised of multiple members across a variety of departments, and include a number of engineers from various disciplines. Working together enables a faster more fluid design and development process, sharing knowledge freely to the benefit of the end product. Enabling us to give informed suggestions about tooling configuration and material choices to produce the best outcomes once we know exactly what is required. This ensures the brief is tested, assumptions challenged and all possible options are explored.
> Prototypes & Refinement Process
Solid-state 2D and 3D vision systems, which make it easier to assess parts quickly, or to establish virtual 'gauges' to fully measure and robustly review a given feature. Then creating 3D prototypes allows the team to reflect on the physicality's of the moulded part and make any additional changes identified to enhance the design of the end product.
> Primary Manufacturing
Here we can further explore operational efficiencies that will reduce costs, speed time to market, and maintain price points. This includes how we can possibly provide more services under one roof, to shorten the supply chain.
> Quality and Testing
Our strong quality management systems are designed to save you time and money. Ultimately getting the product to market faster, with fewer problems or manufacturing inefficiencies, is the objective of this entire process.
A track record of performance and process improvements
We understand OEM's want fast-track turnaround time for product cycles, starting from concept through prototype, pilot run, validation, launch, and scale-up production. But, we also understand the need to focus on continuous improvement, to produce the highest-quality injection-moulded product with the best quality, tolerances, and repeatability.
- The process starts with a complete customer briefing, during which a full specification is taken and a design and manufacturing plan developed.
- Once we know exactly what is required, we can make informed recommendations about tooling configuration and polymer selection to produce the best results.
- We then produce 3D prototypes that allow us to make further adjustments to the design until everyone is satisfied.
- At that stage, the primary manufacturing production goes ahead, and we work to fulfil the order using the approved mould and following the agreed schedule.
- The plastic injection process is then completed with a full round of quality checks.
Medical and health care products that have been injection moulded:
- Plastic injection moulding is so versatile that the components and tools that it produces are used across the global military and defence sectors.
- Disposables
- Implants and Orthopaedic Devices
- Surgical Instruments
- Diagnostic and Patient Monitoring Components
- Medicine Delivery Systems
- Ophthalmic Devices
- Medical Packaging
Injection moulding has many applications in the medical sector, and is a popular and versatile process for manufacturing a variety of plastic products building long-term relationships with our customers by managing the journey from concept design through to manufacturing and logistics.