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Microsystems has developed fully closed loop multi-cavity moulds which monitor and adjust melt temperatures in each cavity. This has significant benefits in terms of the part quality and repeatability. These benefits are fully appreciated by our customers that require multi-cavity moulds or micromolds for use in the medical and dental industries.
High aspect ratio micromolding for application in dental surgeryA new type of dental surgery device (micro engineered by Microsystems using micro injection molding) has been developed for root canal treatment. One of the key challenges in taking the concept to reality was that of finding a mass production method to make a high aspect ratio x-ray opaque core with a tip diameter of less than 0.2mm. The solution to this has been found through innovative tooling design and micro-moulding. The dental device is used to fill the cavity created when the root and nerve of a tooth are removed, typically because of infection caused by decay or injury. Traditionally, a thin plug and sealant are inserted after cleaning, but this procedure can leave voids in the canal and result in subsequent infection that requires the procedure to be repeated. The radio-opaque core of the 'smartpoint' device is coated with a hydrophilic polymer coating, which expands laterally as it absorbs water from the tooth; this creates a tight seal that prevents re-infection.
Micromolding facilitates the miniaturisation of medical device components in plasticsMolding of plastic 'micro-scale' components or parts that have micro-scale/nanoscale features has become increasingly possible over the last few years through developments in processing technology and in machining and mould manufacturing techniques. Examples of micro-moulded medical components include parts featuring miniature holes and meshes, surfaces with sub-micron structures, overmoulded micro-inserts, and combinations of dissimilar materials for drug delivery devices.
Developments in multi-cavity hot-runner tooling for medical moldsMulti-cavity molds with 16, 32, or more impressions, are a long-established method of manufacturing large production quantities of molded medical device components. Such moulds are fed by hot runner systems, often with pneumatically operated valve gates. The use of valve gates as against hot tips improves the accuracy of the moulding as the polymer in the mould gate can be kept in a molten state until an exact preset time when the gate is closed. Despite this, controlling the accuracy of all the parts moulded in multi-cavity tools can be challenging, and various systems have been developed aimed at improving the process control.
Micro molding and nano-structuring for medical and biotech devicesThe continuing industrial interest in micro-components and micro/nano structuring of devices is being driven by increasing needs for point of care diagnosis, portability, minimally invasive surgery, and other factors outside the medical device industry that require miniaturisation. In addition to the established know-how in production micro-moulding, there is a technology push from research and development as methods are developed to design at the nano-level and to achieve specific component functionalities. |
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