Micro Molding and the Future of Biomedical Applications

Paul Runyan, VP Sales & Marketing, Accumold

In the dynamic medical field, micro molding has increasingly become the foundation for innovation, particularly in the creation of cutting-edge biomedical devices. This article explores the transformative impact of micro molding within the biomedical industry, and highlights how the unparalleled precision, scalability, and customization offered by micro molding are paving the way for future breakthroughs in patient care. Furthermore, we examine how these technologies facilitate the miniaturization of devices, making procedures less invasive and more efficient, thereby significantly enhancing patient outcomes. The insights presented underscore the critical role that micro molding plays not only in current medical device development but also in shaping the future landscape of healthcare technologies.

MICRO MOLDING

Micro molding is a specialized manufacturing technique that involves the production of extremely small components, crafted from broad palette of different polymers, and characterized by their high precision and meticulous accuracy. The significance of micro molding is highlighted by its critical role in the development of miniature medical devices featuring intricate shapes and made from advanced, high-performance materials, which are increasingly required for innovative healthcare applications. These applications include, but are not limited to, tiny implants, sophisticated surgical tools, and advanced diagnostic equipment. This capability to fabricate small-scale, complex components is essential as it supports the advancement of medical technology and enhances the functionality and effectiveness of medical treatments.

The primary advantage of micro molding lies in its exceptional precision. This technique is essential for producing medical devices such as stents, catheters, and wearable sensors that must meet not only specific dimensional requirements but also stringent health and safety standards. Micro molding achieves this by allowing the production of components with ultra-fine tolerances, often in the range of just a few microns, and it does this repeatably, there being a demand for zero failure rates in safety critical applications.

Additionally, scalability plays a crucial role in the widespread adoption of micro molding for medical applications. Once a mold is precisely engineered, manufacturers can rapidly produce large quantities of components. The capability to scale up production means that components can be manufactured in the thousands or millions, facilitating quick distribution and significantly reducing the cost per unit. Such scalability is particularly advantageous for the production of high-volume items like medical diagnostic test strips, which require consistent quality and reliability.

Another significant benefit is the extensive customization possibilities micro molding allows. The process can be finely adjusted to create unique geometries tailored to specific medical needs. This level of customization not only applies to the physical shape of the components but also extends to the choice of materials used, enabling the production of devices that meet exact requirements for flexibility, biocompatibility, or biodegradability. By combining these customized solutions with micro-level precision and scalability, micro molding stands out as a transformative technology in the biomedical field, supporting innovations and improving patient care

IMPACT ON PATIENT CARE

The miniaturization of medical devices through the use of micro molding is significantly transforming patient care. By reducing the size of these devices, they become less invasive and more comfortable, enhancing patient comfort and potentially accelerating recovery times while minimizing the risk of post-operative complications. For example, smaller implants can be placed through less substantial incisions, minimizing tissue damage and promoting quicker healing.

Additionally, micro molding allows for the seamless integration of sophisticated electronic components within medical devices. This advancement heralds a new era in personalized medicine, where devices are not only capable of passive tasks but can actively monitor vital signs, administer medications, and dynamically adjust their operations based on real-time changes in the patient’s condition. This capability could lead to highly individualized treatments and interventions, further improving medical outcomes and patient well-being.

PIONEERING TECHNIQUES AND INNOVATIONS

Companies like Accumold are leading innovators in the field of micro molding, consistently pushing the limits of what can be achieved in manufacturing tiny, precise components. Accumold excels in creating micro-molded plastic parts that are used across various critical sectors such as medical, the company utilizing proprietary micro molding techniques to manufacture parts that are not only smaller than a grain of sand but also feature intricacies that measure just a few microns across.

The sophistication of Accumold’s operations is reflected in the company’s in-house production of specialized micro tooling designed specifically for the vagaries of micro-scale production. The company also uses advanced polymers that are tailored to the specifics of a particular application, ensuring that each part meets rigorous standards of quality.

Accumold’s pioneering work in the area of micro molding is especially significant in the medical industry, where its advancements are making way for the development of more complex, reliable medical implants and devices. This technological progress is crucial for the evolution of medical treatments and equipment, setting new benchmarks in the healthcare sector and beyond. Their ongoing commitment to innovation and excellence in micro molding continues to open up new possibilities and applications, driving forward the capabilities of miniature manufacturing technology.

One such is the recent announcement that Accumold has found a way to micro mold thin wall cannulas in very high volumes. Micro injection molding enables the creation of intricate and consistent cannula designs with precise wall thickness control. It eliminates the need for separate extrusion, tipping, and gluing steps by producing the entire cannula in a single mold, enhancing product reliability and reducing the risk of defects. This approach not only improves the quality and reliability of the cannulas but also offers a more scalable and cost-effective solution for meeting the demands of high-volume production in the medical industry. Micro molding cannulas at volume with an outside diameter of 0.035”  (0.889 mm), an inside diameter is 0.027” (0.6858 mm), and a wall thickness of 0.004” (0.1016 mm) is routine at Accumold.

FUTURE DIRECTIONS AND TECHNOLOGIES

The future of micro molding in biomedical applications looks highly promising, with several innovative directions that could significantly impact medical treatments and patient care. One key area of interest is the use of biodegradable polymers, which are already used in — but are poised to revolutionize — the field of implantable medical devices. These polymers can be used to create temporary implants or scaffolds that naturally dissolve within the body once they have served their intended purpose. This capability effectively eliminates the need for a subsequent surgical procedure to remove the implants, thereby reducing the overall risk and discomfort for patients.

Furthermore, the integration of nanotechnology with micro molding represents another exciting frontier. By embedding nanoparticles or nanostructures into the molded components, manufacturers can dramatically enhance the functionality of these devices. For instance, the addition of nanoparticles can increase the electrical conductivity or thermal resistance of the implants, which can be crucial for devices that require these properties to function correctly. Additionally, incorporating nanostructures can lend antimicrobial properties to the implants, greatly reducing the risk of infections post-surgery and during the healing process.

These advancements not only aim to improve the quality and efficacy of medical treatments but also strive to reduce the overall healthcare costs by minimizing the need for additional surgeries and by extending the longevity and functionality of implantable devices. As research continues to advance in these areas, the possibilities for new applications and improvements in micro molding technology are virtually limitless, promising a new era of sophisticated, tailor-made biomedical solutions that cater directly to the evolving needs of patients and healthcare systems worldwide.

CHALLENGES AND CONSIDERATIONS

Despite its numerous advantages, micro molding also confronts several challenges. The exceedingly precise nature of this manufacturing process necessitates advanced design strategies and meticulous quality control measures to guarantee that every component adheres to the required specifications. Furthermore, the creation and integration of innovative materials and processes demand substantial investment in research and development. Obtaining regulatory approval for these new methodologies can be a complex, time-consuming, and expensive endeavor.

This requirement for continuous innovation and compliance can significantly slow down the speed to market, impacting the overall efficiency and cost-effectiveness of micro molding projects. Additionally, the high level of technical expertise required to implement and manage these sophisticated processes can pose a barrier to entry for many companies, potentially limiting the broader adoption of micro molding technologies in various industries. This all shows the necessity of working with an experienced and expert micro molding innovator like Accumold which can act as your qualified micro molding partner and help you navigate the challenges inherent in the process.

SUMMARY

Micro molding technologies hold a key to future biomedical advancements, offering unmatched precision, scalability, and customization for medical device manufacturing. As the technology continues to evolve, it promises to further revolutionize patient care, making treatments less invasive, more effective, and highly personalized. The ongoing developments and innovations in this field are not just enhancing existing applications but are also opening up entirely new possibilities in the medical sector.

This exploration of micro molding technology underscores its vital role in shaping the future of biomedicine, highlighting both the current capabilities and the potential for future breakthroughs that could redefine healthcare as we know it.

www.accu-mold.com

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Record-Breaking NPE2024: The Plastics Show Officially Wraps in Orlando

NPE2024 Captivates and Inspires Global Leaders and Rising Stars  to Shape the Future of the Plastics Industry

 NPE2024: The Plastics Show concluded a momentous week with an incredible turnout that has reinforced its position as the premier plastics industry event in the Americas. Over 50,000 registrants signed up for the show.

This year’s show welcomed new faces, with 63% of attendees experiencing their very first NPE. NPE2024 has made history with one of the youngest audiences ever recorded. 30% of attendees were under the age of 40, marking the growing enthusiasm for innovation, sustainability and the promising future of the plastics industry.

NPE2024’s global reach reestablished its reputation as the international gathering place of the plastics industry in the Americas. More than 15,000 international registrants marked the most international show in NPE’s history. Representatives from 133 countries – or 68.2% of nations worldwide – registered to attend the global plastics trade show. This is a 9.9% increase of countries registered at NPE2018, demonstrating the exchange of industry innovation and ideas on a global scale, and further shaping the path of international plastics collaboration and solutions. This strong international presence was further underscored by sold-out events like the FLiP & Sip Reception, drawing in more than 1,000 attendees and the Women in Plastics Breakfast, which attracted almost 600 attendees

“Witnessing the entire plastics industry reunite at NPE2024 was truly inspiring,” said Matt Seaholm, PLASTICS’ President and CEO. “We were thrilled to welcome familiar attendees, visitors from all over the globe and the next generation of plastics professionals. We cannot wait to see the incredible innovations and collaborations that will emerge from everyone who attended and are proud to say that we produced a historic, can’t-miss event in the plastics industry.”

To get a recap of NPE2024, visit npe.org/npetv for daily episodes of the innovations on the show floor. The NPE team looks forward to the next show happening May 3-7, 2027, in Orlando, FL. For updates on NPE2027, visit NPE.org.

The Plastics Industry Association (PLASTICS) is the only organization that supports the entire plastics supply chain, including Equipment Suppliers, Material Suppliers, Processors, and Recyclers, representing over one million workers in our $548 billion U.S. industry. PLASTICS advances the priorities of our members who are dedicated to investing in technologies that improve capabilities and advances in recycling and sustainability and providing essential products that allow for the protection and safety of our lives. Since 1937, PLASTICS has been working to make its members, and the seventh largest U.S. manufacturing industry, more globally competitive while supporting circularity through educational initiatives, industry-leading insights and events, convening opportunities and policy advocacy, including the largest plastics trade show in the Americas, NPE2024: The Plastics Show.

npe.org

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Focus on extenders & fillers: Bismuth – An environmentally friendly Critical Mineral with growing consumption in new technologies and the green economy

Robin Goad, President & CEO, Fortune Minerals Limited, gives a comprehensive overview of bismuth, one of the common extenders and fillers for the coatings industry, including its applications, developing markets, challenges and opportunities in the market

The world is in a transformational energy transition to renewable power systems and new technologies enabled by a completely different suite of raw materials needed to support the growing green economy. Many of these materials are commonly referred to as “Technology Metals” and are identified on country specific “Critical Minerals” Lists. Minerals considered “Critical” have important uses in essential industries and defense, cannot be easily substituted by other materials, and have concerns about their current sources of supply due to geographic concentration of production, geopolitical issues and/or policy risks, or they may come from countries with Environmental-Social Governance (“ESG”) practices that are not aligned with western democratic standards and values.  New supply sources in reliable countries are therefore needed to diversify production and mitigate risks.

Bismuth is identified as a Critical Mineral by most Western economies because of its unique physical and chemical properties, growing consumption, and supply chain risks due to China’s control over 75% of the global production and 60% of world reserves.  The bismuth market is approximately 20,000 metric tonnes per annum, but consumption is expected to grow at about 7.5% CAGR between now and 2030.

Bismuth is a silvery-white metal that can give colourful iridescent tinges on oxidised surfaces. It has very high density, a low melting temperature and it is the most diamagnetic of all metals. Bismuth also has very low thermal conductivity and high electrical resistivity, but when deposited in sufficiently thin layers on a substrate, it is a good semiconductor. When alloyed with copper and strontium, bismuth is a superconductor. Bismuth is also one of the few metals that expands when cooled, increasing the volume by 3.32% on solidification.  It is therefore used to make low-melting temperature typesetting alloys and castings where it compensates for the contraction of the other alloying metals to form isostatic or dimensionally stable alloys or compounds.  Bismuth is also non-toxic, environmentally safe and has anti-bacterial properties, leveraged in the pharmaceutical and cosmetics industries to make medicines like Pepto-Bismol .

Bismuth applications

Bismuth coatings have historically been responsible for the greatest demand in the bismuth market, particularly from the automotive sector.  Glass frits are decorative coatings applied to automotive windshields and glass panels to protect the glues that seal and bond the glass to the car frame.  The high density of bismuth provides a barrier to block sunlight and also protects the seal from expansion and contraction during changing temperatures.

Some automotive manufacturers use bismuth containing alloys to coat metal frames and body panels to provide protection from corrosion. The low melting temperature of bismuth reduces energy consumption in the melt and the expansion properties during cooling reduces and the risks from shrinkage cracking when the hot metal alloy cools after being electro-plated.

Bismuth Vanadate pigments are valued for their bright yellow, highly saturated colours characterised by outstanding opacity/hiding power, chemical resistance, excellent weatherability and durability. Bismuth mitigates lead-toxicity concerns in this application and is environmentally safe. Bismuth iridescence is also leveraged to make pearlescent paints and metallic paint lustres.

Bismuth also has non-coating applications in the automotive industry, including self-lubricating abrasives used to make clutch and brake friction pads.

In the residential and commercial construction industry, the low melting temperature and reduced volume of bismuth during heating is leveraged to make the trigger mechanisms for fire depressant sprinkler systems. These properties are also valued in the nuclear energy industry, with some reactor designs using bismuth as a reactor coolant. The high density is also now used to make no-toxic radiation shielding foils and x-ray bibs.

Growth and developing markets for bismuth

Growth in the bismuth market is primarily attributed to lead replacement because of concerns over lead-toxicity and legislation that has banned lead use in potable drinking water sources, consumer products and for workplace materials.  Bismuth is scientifically recognised as environmentally safe and non-toxic, but otherwise has similar physical and chemical properties to lead. It is therefore used to replace lead in brasses and solders used for the wetted surfaces of potable drinking water sources (e.g. faucets, valves and water metres).  Bismuth solders are also used in the electronics industry.  Bismuth also replaces lead in free machining steels and aluminium, hot dip galvanising alloys, radiation shielding, glass, ammunition, and fishing sinkers.

There is a new, rapidly expanding market for bismuth metal, making environmentally safe, high density and impermeable plugs to permanently seal oil and gas wells when they are decommissioned, preventing greenhouse gas leakage, blowouts and groundwater migration.  Bismuth-tin alloy is used in this application because of the low melting temperature and low viscosity of the melt which fills the porosity. The alloy expands 1% upon cooling to make an impermeable seal to permanently plug the hole and eliminate greenhouse gas leakage.  Tin is used in the alloy to mitigate the brittleness of bismuth and reduce the expansion properties of bismuth so that the host rock is not fractured from the expansion.  This method is now used extensively for offshore well plugging in the North Sea and Gulf of Mexico, where individual plugs can consume up to 10 tonnes of metal.  The method already accounts for approximately 10% of bismuth metal consumption and is now being used to plug terrestrial wells. Notably, there are more than a million abandoned oil and gas wells in North America alone that have been improperly decommissioned and are leaking gases into the atmosphere.

Another important developing market for bismuth metal is in the manufacture of manganese-bismuth permanent magnets. The performance of these magnets was recently validated by the U.S. Department of Energy at their Pacific Northwest Laboratory and they were found to be cheaper and superior to rare earth element (REE) magnets in some applications.  The magnets have potential use in the powertrains for electric vehicles (EV’s) with direct current (DC) powertrains, which dominate the EV industry.  Two Korean magnet companies and an unidentified OEM are in the process of commercializing theses manganese-bismuth magnets for eMobility.

Bismuth is used in defense to make directed energy weapons.  This, and other applications led the U.S. Department of Defense to add bismuth to the list of Critical Minerals prioritised for DPA Title III funding support.

The bismuth price in North America is approximately US$4 to US$4.50 per pound and reflects a 25% tariff levied on Chinese bismuth supply by the U.S. Government.  The price has been steadily recovering from increased market demand and absorption of a previous surplus of metal that was held by the now defunct Fanya Metals Exchange in China.  Prior to this surplus, the price had traded between US$8 to US$10 per pound and attained has reached a historic high price of US$23 per pound.

Fortune Minerals Limited (Fortune) is developing its vertically integrated NICO Cobalt-Gold-Bismuth Copper Project in Canada, comprised of a planned mine and concentrator in the Northwest Territories and a hydrometallurgical refinery near Edmonton, Alberta. While primarily a cobalt-gold project, NICO is the largest deposit of bismuth in the world, containing 12% of global reserves.  When it is developed, the NICO Project will produce cobalt sulphate for the lithium-ion battery industry, gold doré, bismuth ingots and copper, as well as gypsum as a process by-product.  The NICO Project will provide an important new North American source of cobalt, bismuth, and copper Critical Minerals to diversify the supply chain with a countercyclical and liquid gold co-product.

The NICO Project is an advanced development stage asset that Fortune has already expended more than C$137 million to advance from an in-house mineral discovery to a near shovel-ready development asset with a positive Feasibility Study, environmental assessment approval and the major mining permits.  The NICO Project Feasibility Study is planned to be updated at to reflect recent optimisations and average annual production of 1,800 metric tonnes of cobalt (~8,780 tonnes of cobalt sulphate), 47,000 Troy ounces of gold, 1,700 tonnes of bismuth in ingots, and 300 tonnes of copper in a cement precipitate. Fortune has also entered into a process collaboration agreement with Rio Tinto to assess the feasibility of processing waste streams from the Kennecott smelter in Utah, U.S.A. at the Alberta refinery and increase bismuth and cobalt production. This cross-border initiative is aligned with the U.S. – Canada Collaboration on Critical Minerals Supply. Fortune is also aware of other potential feed sources that could be processed at the Alberta refinery to augment metal production.

fortuneminerals.com

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Hempel to Divest J.W. Ostendorf and Renaulac as Next Step on Strategic Journey

FEICA 2024 Open for Registration

SONGWON Signs the Antwerp Declaration for a European Industrial Deal

Songwon Industrial Co., Ltd., one of the largest manufacturers of polymer stabilizers in the world and a key global specialty chemicals player, has signed The Antwerp Declaration for a European Industrial Deal. Together with 1000 industry signatories representing 25 sectors across Europe, SONGWON will be strengthening the competitiveness, sustainability and resilience of European industrial production, facilitating the transition towards a greener economy and developing sustainable practices across the industrial value chain in Europe.

The Antwerp Declaration underscores the urgent need for clarity, predictability and confidence in Europe’s industrial policy to achieve climate neutrality by 2050, amidst formidable challenges calls for an action plan that fosters sustainable industrial advancement by streamlining regulations, mitigating conflicting objectives, simplifying legislation and reducing over-reporting.  importantly, it aims to position Europe as a competitive global energy provider, emphasizing the urgency of critical infrastructure development, increasing raw material security and driving demand for sustainable products.

“SONGWON strongly supports all of these objectives and they align with our sustainability commitments. Europe continues to be a significant market for SONGWON and we have had a presence for well over a decade, manufacturing a variety of products including key antioxidants and light stabilizers at our Greiz plant in Germany,” said Thomas Schmutz, Leader of Technology, Regulatory Affairs & Sustainability at SONGWON. “We are proud to support The Antwerp Declaration and look forward to working together with other European partners to advance a more circular and sustainable industrial ecosystem that paves the way for tomorrow’s climate solutions.”

SONGWON’s road to net zero emissions
SONGWON aims to achieve net zero emissions by 2050 and has a comprehensive carbon reduction roadmap to help it achieve its target.

For SONGWON, sustainability is a strategic driver and it has integrated environmental, social, and governance (ESG) considerations into its corporate strategy. Embracing sustainability, optimizing operations, fostering innovation and aligning business needs with the continually evolving demands of its markets, environment and society, enables SONGWON to create lasting value.

“At SONGWON, sustainability is a group-wide challenge that involves our entire global team. We constantly strive to deliver more value by creating better environmentally sound solutions using more sustainable, ethically sourced materials that require less packaging and generate less waste,” explained Schmutz. “By harnessing our innovation capabilities, we support customers to overcome challenges and secure a competitive edge through sustainable value creation.”

As an internationally operating organization, SONGWON is exposed to numerous risks that are intrinsically linked with all of its business activities. During an almost 60-year journey of continuous growth and expansion worldwide, the company has increased its ability to navigate challenges, adapt to changing needs and actively prepare for the future. The Antwerp Declaration provides a valuable platform for collaborating and keeping at the forefront of key sustainability innovations, opportunities and challenges.

www.songwon.com

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