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As an injection mold manufacturer specializing in medical case molds, we cover 20 product categories including home appliances, daily necessities, medical devices, digital products, connectors, and electronic components. Below is a practical, hands-on case study following the "Problem-Analysis-Solution-Outcome" framework—tailored for solution evaluation and strategic decision-making—with a focus on medical-grade durability and sustainable practices.
A leading medical equipment enterprise faced urgent challenges with portable medical case molds:
• Poor sterilization resistance: Cases cracked after 20 autoclave cycles (required 100+ cycles at 134℃)
• Insufficient load-bearing capacity: 8% of cases deformed under 15kg medical device weight
• Inadequate waterproofing: IP65 rating failed, causing 10% internal instrument moisture damage
• Unsustainable processes: 23% plastic waste rate and 12.1kW·h/cycle energy consumption failed green certifications
• Material mismatch: Generic ABS lacked heat resistance for repeated autoclaving
• Structural flaw: Traditional mold cooling channels led to uneven shrinkage, weakening structural integrity
• Standard inconsistency: Incompatibility with DEM/HASCO/MISUMI medical mold standards delayed regulatory approval
• Sustainability oversight: No design optimization for recycled medical-grade plastic flow
We developed a targeted solution aligning with medical rigor and sustainability:
• Material & Standards: Adopted PC/ABS medical-grade alloy (heat-resistant up to 150℃), fully compatible with DEM, HASCO, MISUMI, and Mold-Bao standards; supported STEP/X_T drawing formats for seamless regulatory documentation
• Process Innovation: Applied digital twin mold flow simulation to optimize rib structure, designed conformal cooling channels to reduce temperature variation by 50%, and integrated reinforced corner molding for load-bearing enhancement
• Eco-Innovation: Used 90% recyclable mold base materials, upgraded to servo-driven injection systems, and optimized runner design for 32% PCR (post-consumer recycled) medical plastic compatibility
• Compliance Focus: Integrated ISO 13485 quality management, ensuring mold traceability and biocompatibility compliance
|
Metric |
Before |
After |
Improvement |
|
Sterilization Resistance |
20 cycles |
120 cycles |
500% extension |
|
Load-Bearing Capacity |
12kg |
20kg |
66.7% enhancement |
|
Waterproof Rating |
IP65 |
IP67 |
Tier-up protection |
|
Energy Consumption |
12.1kW·h/cycle |
6.8kW·h/cycle |
43.8% cut |
|
Carbon Footprint |
8.5kg CO₂/10 units |
3.9kg CO₂/10 units |
54.1% reduction |
Trend Insight: Over 18 months, the client’s medical case line passed EU CE and US FDA certifications, securing contracts with 5 global medical chains—directly driven by the mold’s durability and sustainability.
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Main Product:
Plastic Mold,
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overmoulding,
Automobile mold,
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Precision part processing
