Machining Challenges
“In the medical mold and die industry, customers face even more challenges than in a typical environment due to the incredibly small sizes and the high precision that is required,” comments Steven, president of First-rate mold company  “That is key—high precision—smaller items with tighter tolerances and better surface finish.

Even though everything is smaller in this industry, in a way everything is exaggerated—the ratios can be extreme—you might be using a 2-mm diameter tool that is 30 mm in length, a 15:1 length to diameter ratio.”

  Steven strongly recommends looking at the overall system in the high-speed machining prevalent in medical, not just the tool or insert. “Good balance is where it all begins,” he comments. The Seco EPB line, for example, uses solid carbide end mills in applications where precision and high speeds are important, such as medical.

 Component Offerings
Another product that meets demanding requirements in the medical market are the new needle bearing locks from Progressive Components that provide precise registration between the two halves of the tool. As the locks engage, the bearings provide additional lifting power without metal-to-metal wear, says Steven,

 EDM Enhancements
EDM machinery manufacturers are dramatically upgrading product offerings for the medical moldmaking market.

  Mitsubishi EDM  last year unveiled the MD+PRO, which features a PM4 control that enables full automation from rough to finish machining. Stepped shape capabilities allow machining of multiple parts with different shapes and thicknesses without setting specific electrical conditions. The new machine comes standard with 0.006-in to 0.012-in wire capable automatic threading and all-axis absolute control, allowing very accurate positioning without returning to zero after power failure.

   First-rate mold company is targeting technology innovation in the medical market on the wire side of the business. “Our new CC generator provides very high cutting speeds and clean surface finishes because medical users want an absolute minimum of deposits on the final workpiece,” comments Steven. The CC generator is a digital generator that features a new spark design, increasing maximum voltage by 25 percent and tripling maximum amplitude to 1,200 amps. Cutting speed in tool steel can reach a high of 42 square inches an hour. The previous top speed was about 37 square inches an hour. The CC generator prevents oxidation on the titanium parts often used for hip and other implants. It also maintains a surface integrity that is free of brass and zinc materials that can come from the electrode during the cutting process.

 Hot Runner Advancements
Another example of a technology innovation aimed at the medical market is the Melt-Disk from Mold-Masters Limited (Georgetown, Ontario), which allows side-gating into parts such as syringe barrels where top gating is not possible. “There are two primary benefits,” says Steven “The first is that you are able to side gate with a hot tip. I always mention the hot tip because you can edge gate, but you end up with a cold slug riding in the part. The second benefit is that you are getting multiple gates (up to eight) with one Melt-Disk. You can mold the same number of parts with fewer nozzles.”

  First-rate mold company already has about an applications for the Melt-Disk, some of them in the beta stage. All nozzle lengths are available for the Melt-Disk, 28–148 mm. A wide range of materials, from polyethylene to polycarbonate, is being used and First-rate mold company is testing use of glass-filled compounds now. Individual heat control in the gate area opened up the materials’ range dramatically with the Melt-Disk. Thermal profile across the Disk is excellent, probably within 3°C from tip to tip, says Steven.     

About First-rate Mold Solution Co., Ltd.
First-rate Mold Solution Co., Ltd. in China, provide industry design,mold design,mold manufacturing,molding analysis,project management service.

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