| Quantity: | |
|---|---|
25099
YIXUN mold
8480419090
| Parameter | Full Details |
|---|---|
| Mold Name | PP 1×48 Cavity 3mL Medical Syringe Barrel Injection Mold |
| Target Product | 3mL Disposable Medical Syringe Barrel (cylindrical, precision inner/outer dimensions) |
| Product Material | Medical-Grade Polypropylene (PP) (ISO 10993 biocompatible, gamma-sterilizable) |
| Cavity & Core Layout | 1×48 Cavity (48 parts per cycle), balanced radial symmetry |
| Gate System | Side Gate with Large Sprue (cold runner system, balanced melt flow) |
| Mold Steel | Cavity & Core: S136 Stainless Steel (heat-treated to HRC48–50); Mold Base: P20 or equivalent |
| Surface Finish | Medical-Grade Mirror Polishing (Ra ≤ 0.025μm, SPI A-1 finish) |
| Tolerance Control | ±0.01mm critical dimension tolerance (inner bore, outer diameter, flange) |
| Cooling System | High-efficiency, evenly distributed water channels (linear + baffled design for cores) |
| Mold Life | ≥ 5,000,000 cycles (under proper maintenance and operating conditions) |
| Ejection System | Pin ejection (core pins + ejector sleeves for uniform, damage-free part release) |
| Operating Conditions | Cleanroom-compatible, temperature-controlled production environment |
Material Choice: S136 stainless steel is selected for its exceptional corrosion resistance, wear resistance, and ease of polishing. At HRC48–50, it balances hardness and toughness to withstand high-pressure, repetitive injection cycles while maintaining precision bore dimensions for syringe barrels.
Layout Symmetry: The 1×48 cavity arrangement is engineered for perfect melt flow balance, ensuring every cavity receives identical melt pressure and temperature, eliminating shot-to-shot variation.
Polishing Process: All core pins and cavity surfaces undergo multi-step diamond polishing to achieve a mirror finish. This eliminates micro-roughness that could trap contaminants, ensuring the syringe barrels are sterile-ready and free of burrs that could compromise safety or assembly.
Side Gate Design: The side gate is strategically located on the non-functional flange area of the syringe barrel, leaving the critical inner bore and outer surface completely free of gate marks. This ensures no impact on the barrel’s sealing, sliding, or visual quality.
Large Sprue Cold Runner: The large sprue design optimizes melt flow distribution across all 48 cavities, preventing pressure drop and ensuring uniform filling even at high injection speeds. The cold runner system is simple, reliable, and easy to clean, making it ideal for cleanroom production where contamination risks must be minimized.
Runner Balancing: The runner system uses equal-length branches to each cavity, ensuring identical flow paths and pressure conditions. This eliminates uneven filling, warpage, or dimensional discrepancies between parts from different cavities.
Core Pin Cooling: Each of the 48 core pins features a dedicated cooling channel (baffled or bubbler design) to maintain consistent core temperature, preventing uneven shrinkage and warpage of the syringe barrel’s thin walls.
Cavity Plate Cooling: The mold plates are equipped with evenly spaced water channels, maintaining a uniform mold surface temperature across all cavities. This shortens cycle times and ensures consistent part quality.
Temperature Control: The system is designed for precise temperature regulation (typically 40–60°C for PP molding), critical for minimizing residual stress in the barrel, which could cause dimensional drift over time or affect assembly fit.
Pin Ejection: Ejector pins are placed at the barrel’s flange, applying uniform force to avoid deformation of the thin-walled barrel during ejection. This ensures the part is released cleanly without scratching or distorting the critical inner bore.
Synchronized Ejection: The ejection system is timed to match the mold opening sequence, preventing premature or delayed ejection that could damage the parts or the mold.
Biocompatibility: Medical-grade PP is USP Class VI certified, non-toxic, and suitable for contact with bodily fluids, making it ideal for syringe barrels.
Processing Characteristics: PP’s low viscosity and high flowability are perfectly matched with the mold’s balanced runner and side gate system, ensuring complete filling of the 48 cavities even with thin-walled designs.
Sterilization Compatibility: The material is compatible with gamma irradiation and ethylene oxide (EtO) sterilization, a critical requirement for medical devices.
Cycle Time: With the high-efficiency cooling system, the mold achieves a short cycle time (typically 15–25 seconds per cycle), maximizing output for high-volume medical production.
Pressure Control: The large sprue design allows for controlled, gradual pressure buildup, reducing the risk of flash or over-packing, which is essential for maintaining tight tolerances on thin-walled syringe barrels.
Consistency: The balanced runner and uniform cooling ensure that every barrel has identical wall thickness, roundness, and inner diameter, eliminating rejects due to dimensional variation.
Surface Quality: The SPI A-1 mirror polish ensures the barrel’s inner surface is smooth, preventing piston friction and ensuring accurate dosage during use. It also eliminates potential sites for bacterial growth, supporting sterile medical use.
Dimensional Precision: The mold is built to tight tolerances (±0.01mm) for critical features like the inner bore, flange diameter, and luer lock interface, ensuring compatibility with standard syringe plungers and needles.
Cleanroom Readiness: The mold’s smooth, easy-to-clean surfaces and stainless steel construction make it suitable for use in ISO 7/8 cleanrooms, with no hidden crevices that could harbor contaminants.
Traceability & Documentation: All components are traceable, and the mold can be supplied with full documentation (material certificates, heat treatment reports, polishing records) to meet medical industry regulatory requirements.
Luer lock syringe components
Prefillable syringe barrels
Medical vials and containers
Other thin-walled, precision medical consumables requiring high-volume, sterile production
Cavity Expansion: Options for 1×32, 1×64, or custom cavity layouts for different syringe sizes.
Gate System Upgrades: Hot runner or valve gate systems for zero scrap production, ideal for even higher-volume orders.
Mold Steel Variants: Corrosion-resistant or high-wear steels for specialized medical materials.
Custom Sizes: Mold modifications for 1mL, 5mL, 10mL, or other syringe barrel volumes.
Special Features: Tamper-evident rings, custom markings, or anti-slip flange designs.
Regulatory-Ready Quality: S136 steel, medical-grade polishing, and tight tolerances ensure compliance with medical manufacturing standards.
Unmatched Efficiency: 48 parts per cycle drastically reduces per-unit production costs for large-scale orders.
Long-Term Durability: Hardened S136 steel construction delivers over 5 million cycles of consistent performance, minimizing downtime and replacement costs.
Zero Compromises on Safety: Every design choice—from the gate location to the polishing process—is optimized to eliminate contamination risks and ensure sterile, safe medical parts.
