Case Study: Plastic Injection Molded Polystyrene Diagnostic Kit for the Medical Industry

plastic-small-parts-03Project description:

With our insight into the specialized requirements of the medical industry, a manufacturer of diagnostic equipment approached The Rodon Group to injection mold a lateral flow in-vitro diagnostic test cartridge. As a valuable product in their diagnostic portfolio, this company manufactured the kits in large quantities for use around the globe.

We built quality and cost effectiveness into the injection molding of this product in a number of ways. Material of construction was an FDA compliant, medium impact polystyrene. By accurately predicting the flow properties, shrinkage rate, and other material behaviors, we were able to optimize the mold design to achieve fast cycle times. We EDM finished the mold cavities to provide a fine quality surface on the finished part, and the smooth cavity interiors also facilitated easy releasing of parts from the mold.

By taking advantage of the operational features of our 177-ton hybrid press, which combines the high-load injection capability of a hydraulic press with the high repeatability and energy efficiency of an electric press, we saved production costs while producing a high rate of conforming product. In addition, our automation capabilities enabled us to further reduce production costs by minimizing expensive manual labor.

The cartridge featured overall dimensions of 5/16” x 7/8” x 3 ¾”. Our precision-built mold, combined with microprocessor controlled processes, enabled us to consistently uphold ± 0.002” tolerances over a very long production run. Since our hybrid press is equipped with machine vision capabilities, we provided 100% parts inspection.

As an ISO 9001:2008 certified provider of high volume injection molding services, our turnkey approach to plastic injection molding serves to improve the quality of plastic parts while reducing their overall cost profile.

To learn more about this project, see the table below or contact The Rodon Group directly.

Highlights of this Tool Making & Injection Molded Project

 
Product Description Plastic injection molded diagnostic kit
Capabilities Applied/Processes

Primary:

  • Tooling Design
  • Mold Making
  • High Volume Plastic Injection Molding
Equipment Used to Manufacture Part: 177  ton Nissei Hydraulic Presses
Overall Part Dimensions

5/16" x 7/8" x 3 ¾"

Tightest Tolerances ± 0.002"
Material Used Medium Impact Polystyrene
Material Finish Fine EDM Finish (Electrical Discharge Machining)
In process testing/inspection performed Vision Inspection System (for accurate measurement)
Estimated Part Weight 8 grams
Industry for Use Medical/Diagnostic
Delivery Location Worldwide
Standards Met

iso 9001: 2008
FDA Compliant (raw material used)

Product Name Lateral Flow In-Vitro Diagnostic Test Cartridge