哈尔滨How to reduce the defect rate of injection molded medical equipment products in Dalian?

Dalian injection molded medical equipment products play an irreplaceable role in the modern medical field, with efficient and precise manufacturing processes and strict quality control ensuring product safety and reliability. With the continuous advancement of technology and changes in market demand, injection molded medical equipment products will continue to develop towards intelligence, personalization, environmental friendliness, miniaturization, and multifunctionality, providing the medical industry with more advanced and efficient products, promoting the progress of medical technology and the improvement of human health.

The injection molding process can achieve high-precision dimensional control through precision molds, ensuring product consistency and interchangeability. At the same time, products with microstructures and complex internal structures can be manufactured to meet the needs of different medical functions and improve the effectiveness and convenience of instrument use.

How to reduce the defect rate of injection molded medical equipment products in Dalian?

Optimize mold design and manufacturing

Reasonable design: Based on the product structure and functional requirements, design a reasonable mold structure, including flow channel system, cooling system, demolding mechanism, etc. For example, adopting a balanced flow channel design ensures that the plastic melt is evenly filled into each cavity, avoiding defects caused by uneven filling of the mold.

Strict manufacturing: Select high-quality mold steel to ensure the strength and wear resistance of the mold. At the same time, high-precision processing equipment and advanced processing technology are used to ensure the machining accuracy of the mold, such as controlling the dimensional tolerance of the mold cavity within ± 0.05mm.

Full verification: After the mold manufacturing is completed, sufficient trial molding and debugging are carried out to test and optimize the various properties of the mold. Based on the trial mold results, make necessary modifications and adjustments to the mold until a qualified product is produced.

Strict quality control of raw materials

Supplier management: Select qualified and reputable raw material suppliers and establish long-term stable cooperative relationships with them. Regularly conduct on-site inspections and evaluations of suppliers to ensure their production capacity and quality assurance system meet requirements.

Incoming inspection: When raw materials enter the factory, they are inspected according to strict inspection standards, including appearance, size, physical properties, chemical properties, and other aspects. For example, using an infrared spectrometer to analyze the chemical structure of plastic raw materials to ensure that they meet the specified model and quality requirements.

Storage management: Raw materials should be stored in a dry and ventilated environment to avoid moisture, heat, or contamination. For different batches of raw materials, they should be stored separately and labeled to prevent mixing.

Optimize injection molding process parameters

Process development: During the trial production stage of the product, optimization methods such as orthogonal experiments and Taguchi method are used to determine a better combination of injection molding process parameters. For example, for the injection molding of a certain syringe housing, the optimal injection temperature is determined through experiments to be 220 ℃ -230 ℃, injection pressure is 80MPa-90MPa, and holding time is 15s-20s.

Process monitoring: During the production process, the monitoring system of the injection molding machine is used to monitor and record the process parameters in real time. Once the parameter fluctuations exceed the set range, adjustments are made in a timely manner. At the same time, advanced sensor technology is adopted to monitor online parameters such as pressure and temperature inside the mold, providing a basis for process adjustment.

Continuous improvement: Based on the problems encountered in the production process and product quality feedback, continuously improve and optimize the injection molding process. For example, when shrinkage is observed in the product, the holding pressure can be appropriately increased or the holding time can be extended.

Strengthen equipment maintenance and management

Daily maintenance: Develop a detailed equipment maintenance plan, and operators should carry out daily maintenance work according to the plan, including equipment cleaning, lubrication, fastening, etc. For example, after production ends every day, clean the screws and barrels of the injection molding machine to prevent plastic residue residue.

Regular maintenance: Conduct comprehensive maintenance on the equipment regularly, checking whether there are any hidden faults in the mechanical components, hydraulic system, electrical system, etc. of the equipment. Replace severely worn components in a timely manner, such as replacing vulnerable parts such as screw heads and nozzles of injection molding machines.

Equipment upgrade: Timely monitor the development trends of injection molding technology, upgrade and transform old equipment, and improve equipment performance and stability. For example, upgrading traditional hydraulic injection molding machines to electric injection molding machines can improve injection accuracy and production efficiency.

Enhance personnel skills and management

Training and education: Regularly organize operators to participate in training courses on injection molding technology, equipment operation, quality management, etc., to improve their professional skills and quality awareness. For example, inviting industry experts to give lectures and share advanced injection molding technology and quality management experience.

Performance evaluation: Establish a sound performance evaluation system, incorporate product quality indicators into the performance evaluation system of operators, motivate operators to strictly abide by operating procedures, and improve product quality.

Team building: Strengthen the construction of the quality management team, establish a quality control team, responsible for analyzing and solving quality problems in the production process. Through teamwork, jointly promote the improvement of product quality.

The injection molding process can achieve large-scale production with high production efficiency, suitable for the large-scale demand of medical device products. The design and manufacturing accuracy of injection molds is very high, which can produce products with stable dimensions and smooth surfaces, meeting the strict requirements of medical devices for accuracy. The injection molding process is suitable for various plastic materials, such as polycarbonate (PC), polypropylene (PP), polyethylene (PE), etc., and can meet the performance requirements of different medical device products.

To prevent product contamination, injection molded medical device products usually need to be produced in clean workshops. The workshop should be designed and decorated according to relevant standards, equipped with air purification systems, air conditioning systems, and other facilities to control parameters such as temperature, humidity, and dust particle count in the workshop, ensuring that the production environment meets the requirements.