Micron Solutions Blog

Case Study in Advanced 2-Shot Molding: Specialty Drug Delivery Devices

Posted by Micron Solutions on Apr 18, 2024 11:51:06 AM

As the medical device industry continues to evolve, the demand for innovative and user-friendly medical devices has never been greater. One device that is transforming the lives of patients is a wearable drug delivery device, a critical component that allows individuals to manage their chronic conditions with ease and precision.

At the forefront of this technology is Micron Solutions, a contract manufacturer in Fitchburg, MA, renowned for its expertise in advanced, precision 2-shot injection molding and its commitment to expeditiously delivering cutting-edge solutions for the healthcare industry.

Manufacturing the Drug Delivery Device

The development of a specialty wearable drug delivery device requires a delicate balance of precision engineering and uncompromising quality. Micron Solutions was tasked with manufacturing three key components for this device, each posing unique challenges in terms of material selection, intricate geometry, and seamless integration.

Navigating Intricate Geometries

The design of the drug delivery device features complex, multi-dimensional shapes and intricate features that push the boundaries of traditional molding techniques. Micron Solutions' specialized equipment and advanced 2-shot injection molding process allows the company to capture these precise details with unparalleled accuracy and consistency.

Ensuring Seamless Integration

The three components being manufactured are integral to the overall functionality of the drug delivery device. Achieving a flawless fit and seamless integration between these parts is crucial to the device's performance and user experience.

Micron’s 2-Shot, Multi-Material Molding Approach

To meet the challenge head-on, Micron Solutions leveraged its expertise in advanced 2-shot injection molding, a specialized technique that sets the company apart in the medical device manufacturing industry.

The Power of 2-Shot Molding

2-shot molding, also known as 2-component (2C) molding, is a revolutionary approach that allows the simultaneous injection of two different materials into a single mold. This process enables the creation of highly complex, multi-material parts with precision and efficiency.

Precision Engineering

Micron Solutions' 2-shot molding process allows for the precise integration of multiple materials, ensuring a seamless and cohesive final product. By carefully controlling the injection sequence, temperature, and pressure, the team can achieve intricate geometries and robust mechanical properties that are simply not possible with traditional molding.

Improved Efficiency

Compared to traditional assembly-based manufacturing methods, Micron Solutions' 2-shot molding approach streamlines the production process, reducing lead times, labor costs, and the risk of defects. By consolidating multiple components into a single, high-precision part, the team can deliver a consistently reliable product at scale.

Rotary and “Turn and Flip” Systems

The rotary table and turn and flip system are at the heart of Micron Solutions' molding process features a unique mold design that precisely aligns the two materials, ensuring a flawless bond and consistently high-quality final product. Micron Solutions' experts carefully calibrate and monitor the 2C mold systems to maintain tight tolerances, while its streamlined manufacturing enables rapid production and the versatility to adapt the process for each project's unique requirements.

Using Automation to Ensure Quality

Recognizing the importance of consistent quality in the medical device industry, Micron Solutions invests in automation and advanced manufacturing technologies. The company's multiprocess manufacturing cell for this project is automated and includes secondary processes such as printing, heat staking and in line optical inspection, ensuring a high degree of precision and reproducibility in each step of the production process.

By automating and utilization of high precision cameras at key steps in the manufacturing process, the company minimizes the potential for error, which can be a significant source of defects in medical device production.

This, in turn, enhances the overall quality and reliability of the final product. Furthermore, automation not only improves quality but also boosts efficiency, as Micron Solutions' highly automated 2-shot molding cell can produce parts at a rapid pace, helping the company meet the growing demand for specialty drug delivery devices and other complex medical devices.

Transforming Lives Through Innovative Drug Delivery

The specialty drug delivery device manufactured by Micron Solutions is more than just a medical device. It's a life-changing tool that empowers individuals with chronic conditions to manage their health with greater ease and confidence.

Micron Solutions' commitment to innovation and manufacturing excellence has helped to make this specialty drug delivery devices more accessible to a wider range of patients, as the company's ability to produce these devices at scale, while maintaining the highest standards of quality, has contributed to their widespread adoption and improved access to cutting-edge healthcare solutions.

Advancing the Future of Specialty Drug Delivery

Micron Solutions' expertise in 2-shot injection molding and its dedication to error proof manufacturing excellence have positioned the company as a leader in the development of innovative medical devices. By leveraging its talent team of experts, specialized equipment, advanced manufacturing processes, and commitment to quality, Micron Solutions is helping to shape the future of specialty drug delivery devices and improve the lives of patients worldwide.

As the healthcare industry continues to evolve, Micron Solutions remains at the forefront of innovation, constantly exploring new ways to push the boundaries of what's possible in medical device manufacturing. With its unwavering focus on quality, efficiency, and speed to market, the company is poised to play a crucial role in the ongoing transformation of the medical device landscape.

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