Medical industries usually prefer to use cost-friendly materials and procedures. So, they can increase productivity at lower rates. But yes, pricing changes with different factors. So, In this article, we will explain these factors in detail and how they can be reduced, so look at them as given below.
Overview of Medical Injection Molding Process
Medical injection molding is the most recommended process for simultaneously producing medical products in hundreds or thousands of numbers. According to their requirements, companies use molten plastic of different material qualities in this technique and pass through metal stencils and cold water to get proper-shaped medical goods.
Medical Injection Molding Cost Factors
Stating your query on “What Factors Affect The Cost Of Medical Injection Molding Products,” the points are the following:
1 – Complex And Intricate Product Designs
Complex product design is a significant factor that increases the cost of the molding process. Medical devices with geometric shapes and multiple assembly components require high-profile and precise tools to run the production. These tools are expensive and need a longer time to make products from molding machines. As a comparative statement, the devices with simple design and compromising functions reduce manufacturing expenses and require less time for product settlement. Therefore, medical Industries must use simple and less complex product designs to retain the cost strategies under the line.
2 – Low And High Mold Cavitation
The plastic mold injection process uses low and high cavitations that also impact the production cost. Low cavitation generally has 1 to 4 cavities. It requires low front tools, and there is less chance of any risk or damage in one cavity. Also, these have better classic floor balance and maintain a tight tolerance with more flexibility. On the other hand, high cavitation has eight or more than ten cavities requiring high front tools and less risk of damage because if one cavity is damaged, it will not affect the other samples. Also, it needs more balance to fill the plastic, and the machine part requires more dimensions and a great surface. But significantly, these high cavitation modes require low prices, as you can get out more plastic products in one cycle. Although, all the corresponding risks are manageable by handling the molds properly.
3- Selection Of Mold Material
The choice of mold material is the primary factor impacting the molding cost overall. Molds have different classifications; the most common is 101, which provides more than 1 million cycles with a hardness of approximately 280 BHN with a 48 Rc hard plastic. The material has different cost changes, from simple polyester to biodegradable polymers and from polyethylene to thermoplastic. The biocompatible plastic is more expensive than the other plastics. So, rather than using these big-budget materials, medical companies can look for alternatives and efficiently manage manufacturing expenses.
4- Mold Fabrication Methods
There are three top-notch mold-generating machines: CNC Machine, 3D printing, and Electrical Discharge Machine. These fabrication techniques add a coin to the tool expenses box for mold injection preparation. CNC is a high-end process of making prototype molds using computer-controlled processing machines to remove the material and cause mold cavities and other design features. EDM is the most friendly procedure for large production and complex molds, which uses electrical discharges to evacuate extra material and make the designs precisely. 3D printing is a quick prototyping process, best for low-volume production, and costs less for the output products.
5- Molding Tools
Custom and personalized molds require more investment and detailed tools to make the custom components accurately. The more complex the product’s design, the more molds need die-cuts. Therefore, manufacturers can opt for optimized tools and multi-cavity molds to lessen expenses and explore more simplicity in their medical devices.
6- Mold Finishes And Coatings
Finishing and coating steps counterfeit the charges of molds. The additional manufacturing expenses are the processing steps, including assembling, trimming, and other surface finishing. Medical industries can use other assembly steps to reduce costs efficiently. If the finishing is necessary, choose cost-friendly chemicals to retain the budget.
7- Qualification And Documentation
Medical devices are sensitive equipment and require FDA standards and ISO regulations that involve testing tools and validating the processing work for verification documents. Although all these regulations add to the overall cost of these devices, they are crucial steps to getting reliable, safe, and human-protective medical devices.
8- Raw Material Dealers And Suppliers
Making a good choice of material suppliers and other molding material dealers can prominently reduce the overall cost of the method. The market is full of retail and wholesale suppliers with various materials, robust tools, and competitive pricing. Making a good deal will surely improve the efficiency of your production, so making a good deal will get you budget-friendly molding injection medical devices.
9- Transportation
Transportation is another factor that can not be deniable while calculating the expenditure of molding. Importing raw materials or machinery from far and distant areas, cities, and countries causes an increase in money. Therefore, the manufacturers need to consult the suppliers that are nearby and progressive with low delivery prices.
Conclusion
Summarizing what factors affect the cost of medical injection in molding products, I must include that from choosing the material to mold fabrication and contacting dealers to transportation strategies; medical industries can proficiently reduce the price. All optimizing strategies need efficient product cost calculation while qualifying the product quality. Therefore, manufacturers and designers must tailor the documentation and add risk possibilities before initiating the process.
FAQs
Q1- How can I reduce the cost of medical injection molding?
Ans: You can reduce the prices using automation tools, reusable scrap, standard plastic quality, a low cycle time process, more molds in one time, and low delivery charges.
Q2- What factors enhance the quality of injection molding?
Ans: Good-quality molds require advanced structural designs, precise mold assembly, optimal water flow, an efficient temperature-control system, polishing, and protective coating.
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