Muti-cavity Injection Mold for Overmold Surgical Plastic Parts Service PP TPE Material

Multi-Cavity Injection Mold for Overmolded Surgical Plastic Parts (PP/TPE Materials)

Service Overview

Key Capabilities for Surgical Overmold Molds

1. Multi-Cavity Design (2-16 Cavities)

• Reduces per-unit cost by 30-40% (vs. single-cavity molds).

• Maintains ±0.02mm tolerance across all cavities (via high-precision CNC machining of mold cores/cavities).

• Optimized for small-to-medium surgical parts (e.g., 50-200mm size range):

2. PP + Medical TPE Overmold Compatibility

• First shot: Injects medical PP (rigid substrate) into cavities.

• Second shot: Overmolds biocompatible TPE (Shore 30-80A) onto PP—ensures ≥7MPa bond strength (meets surgical device durability requirements).

• Mold features dual-shot/insert overmold systems (cleanroom-class):

• Material compliance: PP/TPE meet ISO 10993-1/-5/-10 (non-toxic, hypoallergenic).

3. Surgical-Grade Mold Materials

• Mold cores/cavities: Stainless steel (S136H) or H13 tool steel (corrosion-resistant, autoclave-compatible for mold cleaning).

• Surface finish: Ra 0.025μm (mirror polish) to prevent microbial buildup and ensure smooth part release.

4. Cleanroom-Ready Manufacturing

• Mold production in ISO 8 cleanrooms (critical for avoiding contamination of surgical parts).

• Mold components (e.g., hot runners, cooling systems) are sealed to meet medical device hygiene standards.

Service Process (End-to-End Support)

1. DFM & Design Validation

• Cavity layout (balanced flow for uniform overmolding).

• Gate location (minimizes TPE flash on surgical part surfaces).

• Cooling system (prevents PP/TPE warpage in multi-cavity runs).

• Our engineering team reviews your part 3D model (STEP/IGS) to optimize:

2. Mold Fabrication

• High-precision machining (5-axis CNC, EDM) for mold cores/cavities.

• Assembly & testing: Dry-run with PP/TPE to verify cavity fill, bond strength, and tolerance consistency.

3. Sample Validation

• Biocompatibility testing (ISO 10993).

• Functional validation (grip strength, sterilization resistance).

• Provide 50-100 prototype parts for:

4. Mass Production Support

• Assist with injection machine parameter tuning (for 2-shot overmolding).

• Offer mold maintenance (cleaning, component replacement) to ensure 1M+ part lifespans.

Technical Specifications

Why Choose Our Service?

• Medical Expertise: 10+ years of experience in surgical device mold design (no rework for regulatory non-compliance).

• Cost Efficiency: Multi-cavity molds reduce production time by 50% for high-volume orders (100k+ parts/year).

• Traceability: Full documentation (mold material certificates, machining logs) for medical device QMS.