• Specialized in microfluidics, die cutting, laser cutting, screen printing, LSR, plastic
injection molding, bonding (laser & ultrasonic welding), blister packing, dry reagent
handling, assembly, soft goods/wearable manufacturing, and packaging;
• Class 10-100K clean rooms and GMP facilities;
• Offices in Los Angeles (USA) and Singapore;
• Manufacturing sites in Malaysia and China.
Types of Injection Molding Used for Medical Prototypes
Injection molding comes in many forms and each type is utilized based on the desired application for the medical device. Hochuen provides all these injection molding processes based on what application would be ideal for the medical device.
Hochuen has experience injection molding with the following materials: Medical grade PC, PMMA, COC, COP, PS, PP, TPE/TPU, LSR, ABS, etc. Each project however has different requirements and we will work with you to determine what works best for your project.
Injection Molding Type:
Ordinary Injection Molding
Double Color Injection Molding
Hochuen Medical has a large machine shop equipped with high-speed and high-precision CNC machines to make injection molds and fixtures in house. Our turn-around time of prototype molds is 1~2 weeks and production molds is 4-6 weeks depending on the design complexity.
Injection Molding Applications for Medical Device
Injection-molded parts for medical devices can be used in many different applications, including:
Point-of-care Testing IVD devices
Microfludic Cartridge Devices
Off-Shelf Disposables( Vials, Transfer Pipettes, etc.)
|Injection Molding Type
|Description Product precision
|Ordinary injection molding
|All electric injection molding machine,and some high speed machine
High Speed: 0.003~0.005mm
|Double-color injection molding
|Finished part injected by 1 time, including hard and soft
|First hard or soft material and then soft or hard one, twice
|Liquid silicone rubber injection molding
Injection Molding Workshop
|Hochuen Medical Technology Co., Ltd.
|Injection molding, microfluidic devices, adhesive, die cutting, lamination, LSR, bonding (including laser welding, ultrasonic welding, heat staking, etc.), dry reagent handling, reagent blister packing, wet lab process, PCR QC test, CNC precision machining, laser machining, rapid prototyping, label printing, softgood manufacturing, sterilization/packaging,etc.
|ABS, PC, PP, PS, POM, PMMA, PE, PA, HIPS, TPU, PE, BOPP, EPDM, Liquid Silicone Rubber (LSR), etc.
|500,000 Times Shots
|Single cavity or multi cavity
|Hot runner and cold runner
|CNC/Injection Molding Machines
|We have Makino, Fanuc, Sodick, CZPT injection molding machines from 50 tons to 450 tons for prototyping and large volume production.
|Advanced Testing Equipment
|Prismo 3D equipment for inspection, 2D testers and other
|Black, white, clear, red, blue, or according to customer’s requirements.
|Solidworks, DWG, PDF, AI, STP/STEP, etc.
|ISO9001, ISO14001, ISO13485(ALL THE MEDICAL PRODUCTS MEET F.D.A STHangZhouRDS), ISO45001
|Other services offered
|Printing, die cutting, CNC machining, assemblying and packaging, etc.
|T/T or online transactions(by trade assurance) for option
|Medical instrument parts and medical disposables, consumer electronics, sports, beauty and personal care products, baby’s products, biosensors for DNA analysis or chemical research, Medical foams/tapes or thermal insulation pad for other biometrics,small parts for automobile, aviation and aerospace equipments, etc.
|Drawings and quantities will be needed for a detailed quotation. Free Sample will be offered for approval after PO for molding is confirmed.
1.Work with world-class customers and suppliers;
2.Rapid ramp up capability to mass production;
3.Superior quality and cost benefits;
4.Superior engineering development service;
5.Stringent IP protection for clients;
6.Comprehensive in-house manufacturing and engineering capabilities;
7.Fast response and rapid turn-around;
8.Hochuen has been producing detection cartridges for a dozen of
clients during pandemic.
Our Global Business Partners
1.How do you cut the parts?
We have laser cutting, die cutting, CNC machining and stamping.
2.What Certificate do you have?
We have certified with ISO 14001, ISO 45001, ISO 13485, and FDA registered.
3.What kind of injection molding you do?
Normally we have ordinary injection molding, double color injection molding, LSR, overmolding, insert molding, etc.
4.What tons of injection molding machine do you have?
From 50 tons to 450 tons, we mainly focus on consumable medical device, LSR (liquid silicone rubber) also available, and we do mold in house.
5.How do you assemble the parts?
Typically we have PSA bonding, laser welding, ultrosonic welding, diffusion bonding, etc.
6.Are you available only prototyping or from prototyping to manufacturing?
We are an OEM manufacturer, and provide 1 stop service from prototyping to mass production.
All of our products are customized.
Estimated freight per unit.
|To be negotiated
|Surface Finish Process:
Designing Injection Molded Parts
Injection molded parts are designed to work together to form a whole. While the small plastic toys like Legos aren’t typically fabricated for assembly, these products still require precision measurements. For this reason, the designs of injection molded parts should be perfected for manufacturing. The designs should also minimize error potential.
Design considerations for injection molded parts
When designing injection molded parts, it’s essential to consider the wall thickness of the part. Ideally, the wall thickness is uniform across the entire part. This allows the entire mold cavity to fill without restriction, and reduces the risk of defects. Parts that don’t have uniform wall thickness will have high stresses at the boundary between two sections, increasing the risk of cracks, warping, and twisting. To avoid such stresses, designers can consider tapering or rounding the edges of the part to eliminate stress concentration.
The wall thickness of the injection molded part is important because it affects many key characteristics. Therefore, it is critical to take proper care in choosing the wall thickness to avoid costly delays caused by mold problems or mold modification. The nominal wall thickness should be determined based on the function and stress requirements of the part. Similarly, the minimum wall thickness should be calculated based on acceptable stress. Too thin a wall can result in air traps and excessive plastic pressure.
Injection molded parts that have sharp corners are a common cause of defects. Sharp corners create stress concentrations, poor flow patterns, and increased injection mold wear. To minimize these problems, designers should keep inside corners and outside corners at half the wall thickness. This will help minimize stress and ensure the integrity of the part.
Another important design consideration for injection molded parts is the thickness of the ribs. They should be at least two-thirds of the outer wall. Thicker ribs may result in sink marks on the outer surface. Undercuts also complicate the mold design and increase the cost of the part.
Tolerance variation is also an important consideration. It depends on materials, process control, and tool design. Tolerance variation varies from molder to molder, and designers should discuss critical tolerance requirements with molders. If the part has to be manufactured to a particular tolerance, designers should consider options for mold revisions to minimize the tolerance variance. Additionally, designers may need to intentionally design extra clearance. To compensate for such variation, the molder may remove some steel or modify the design. In some cases, interference can be solved by welding.
Design considerations for injection molded parts should be discussed with material science professionals early in the design process. This is critical because changes to the mold design can be costly. Therefore, achieving the best possible result is critical. By following design guidelines, manufacturers can avoid common defects. A uniform wall thickness is also important because non-uniform thickness can lead to warping the part as it cools.
Another important factor for injection molded parts is the flowability of the material in the mold cavity. The resin should be able to flow easily around rounded corners. For example, a molded part with a curved undercut will not eject properly from the mold if there’s no space between the two sides. For this reason, designers should consider the flowability of the molded material before deciding on a design.
Adding a runner system to an injection molding machine
There are two main types of runner systems: hot runner systems and cold runner systems. In a hot runner system, a runner nozzle delivers the molten plastic into the mold cavity. A cold runner system does not require the use of a nozzle and acts as a conduit for the molten plastic.
The design of a hot runner mold should balance the activity of plastic solution and mold cavities. Ideally, a mold with two cavities is better balanced than one with three. However, it is important to remember that a three-cavity mold requires a manifold balance of human activities.
Plastic mold runner systems are crucial for ensuring consistent fill rates and pressure. Whether you are producing single or multiple-cavity plastic parts, a runner system will keep your processes consistent. When choosing a runner system, make sure you have the right one for your application.
Hot runner systems can reduce cycle times by as much as 10 to 30 percent. They help improve quality control and minimize material waste by keeping the plastic molten throughout the molding process. Moreover, they help save on plastic raw materials and energy. These features make them ideal for large production lines.
A hot runner system can also help prevent overfilling a cavity. Make sure that the volume of the hot runner is equal to the volume of the mold cavity. Otherwise, the plastic solution will be trapped inside the hot runner for too long and decompose.
Hot runner systems come in many varieties. One type of hot runner system is called the sprue hot runner system. This system uses a mechanical valve to open and close a nozzle. This type of hot runner is more effective and efficient than a general-purpose hot runner. However, it is also more expensive.
In a three-plate mold, the runner system is positioned between the core and cavity plates. When the mold is opened, the runner system automatically separates from the molded part. This eliminates the need for manual labor, but increases the cost of tooling.
The runner system is important for producing parts that are both thin and thick. The runner should be narrow but large so as not to create voids and improve the overall performance of the final product. Runner systems are also important for reducing the amount of energy needed to form and regrind the material.
A hot runner system is one way to improve the speed and accuracy of plastic molding. It helps avoid problems with waste by reducing the amount of plastic wasted. Furthermore, a hot runner system also prevents expensive repairs. By adding a runner system to an injection molding system, you will ensure better quality and precision, and avoid unnecessary downtime and costly repairs.
Hot runner systems are ideal for high-volume productions. However, they require a higher level of maintenance. In addition, hot runner systems are difficult to clean and often leave waste material. Hidden runners may also be inconvenient to remove, especially when changing materials or colors. They can also lead to sticking issues if they are made from thermally sensitive materials.
Using a thermally isolated cold injection unit
Thermostatic control of temperature in an injection molding process can make a significant impact on part quality. High mold temperatures should be regulated by using a temperature-controlled cooling unit. These devices are equipped with pumping systems and internal heaters. The temperature of the injected plastic determines the plastic’s flow characteristics and shrinkage. Temperature also influences the surface finish, dimensional stability, and physical properties of the finished product.
A thermally isolated cold injection unit allows mold operators to mold parts at lower temperatures than a conventional injection molding machine. The injection mold itself is composed of two steel halves. The two halves are connected by a mechanical hinge. During injection molding, a small amount of plastic is forced into the mold cavity. The injected plastic is then allowed to cool into a solid state. The molded part then falls out of the mold halves. The injected part then enters a bin to be collected.
The heat/cool injection molding process can improve the aesthetics of molded parts significantly. The effects of this technique are particularly apparent with amorphous resins, which do not form a skin during the injection phase. The molded parts have a higher gloss than with conventional molding techniques.
This process requires less clamping force than conventional injection molding and offers more design freedom. It also increases process capacity and materials savings. The process control for this process is more complex, with variables such as the amount of melt injection, water pressure, and water injection delay time.
The angle of repose is another criterion. A low angle indicates that the pellets are free-flowing, while an angle above 45deg indicates that the pellets are not free-flowing. This is important when processing nylon resins.
Plastic injection molding has made huge advances in recent decades. Today, most injection molds fall into one of two types: hot runner and cold runner. Each has its advantages and disadvantages. Understanding how they differ will help you decide which method is right for you.
Injection molding is a highly effective manufacturing process that gives manufacturers a competitive edge over their competition. Using this process produces high-quality plastic and metal parts with minimal waste and a low cycle time. The process is also extremely accurate and produces products with the perfect blend of flexibility and strength.
editor by CX 2023-04-24