With careful planning, complex injection molding can reduce costs, optimize functionality and improve aesthetics in medical devices.

The practice and purpose of qualifying a tool is at the very core of scientific molding. This critical step ensures consistent and repeatable production of flawless molded parts by having engineers push the tool relentlessly under realistic conditions (and sometimes beyond). Their goal is to identify and correct weaknesses before the tool is called into action.

Here’s a look at the basic step-by-step process of scientifically qualifying a tool:

The Kaysun Blog is a valuable year-round resource for advice and information about complex injection molding. We have our subscribers to thank for its continued popularity, and look forward to providing you with even more helpful insights throughout 2019.

For now, let’s take a look back at the four most popular blog posts of 2018:

In the manufacturing world, “lean” principles reduce inventory and work in process, improve quality, boost productivity, and ultimately lower costs. Lean originated in Japan decades ago and has been readily embraced in manufacturing sectors around the world, especially the automotive industry.

With increasing global competitiveness, lean principles have never been more important for making U.S. companies competitive. One of the most simple yet effective lean tools is value stream mapping, which can be implemented within days and can reap impressive results in a short period of time.

There is little room for error when designing plastic parts for critical-use applications. Anything that could stand in the way of uncompromised performance or end-user safety is unacceptable; there’s too much at risk given the potential for significant issues surrounding recalls, warranty claims, property damage and personal injury. And, no company can afford to lose customer trust.

When engineering-grade resins were introduced in the 1950s, some auto manufacturers were unfamiliar with the benefits of metal-to-plastic conversion, i.e. how to design plastics into products, and how to manufacture with plastics. Today this practice, also known as “lightweighting,” is becoming increasingly popular with automakers as they race to comply with a federal mandate calling for automobiles to average 54.5 miles per gallon by 2025.

Up until the 1940s achieving necessary product functionality at the lowest cost was usually done by any means necessary. However, during the height of World War II the scarcity of materials and components drove General Electric engineers to find material substitutes, many of which reduced project costs and improved overall product performance. Thus, the approach of finding cost-effective manufacturing solutions without compromising product functionality or quality — later dubbed “value engineering” — was born.

We all know that carbon dioxide (CO₂) — a greenhouse gas emitted into the atmosphere through the burning of fossil fuels — is a major culprit in environmental degradation.

Companies had tried unsuccessfully for years to find a cost-effective way to incorporate CO₂ into plastic in order to minimize dependence on fossil fuels and substantially decrease greenhouse gases. Recently, however, several plastics manufacturers discovered that using a copper catalyst could be the solution.

Thousands of medical industry professionals, thought leaders and suppliers met in Minnesota October 31-November 1 at Medical Design & Manufacturing (MD&M) Minneapolis 2018 — the midwest’s largest medical technology trade show.

As both an exhibitor and guest at MD&M, the Kaysun team learned a lot about what’s currently happening and evolving in the medical industry. Here are three of the most talked-about trends: