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WITTMANN BATTENFELD presents latest micro injection molding equipment for medical technology at Medtec 2012
WITTMANN BATTENFELD at the Medtec 2012
WITTMANN BATTENFELD is responding to the increasing significance of nano and micro parts in medical technology with its MicroPower, a machine model specially developed for high-precision injection molding of extremely small parts. The all-electric MicroPower - available with clamping forces of 5 and 15 t - is attracting attention from the medical industry by its extraordinary cost-efficiency, process reliability and speed.
In this new machine generation, the innovative two-step injection unit, consisting of a screw and a plunger, with a shot volume ranging from 0.05 to 4 cm³, is of special interest. The melt injected through this injection aggregate is thermally homogeneous, resulting in absolutely top-quality parts, absolutely stable production processes and short cycle times. Thanks to the short cycle times as well as low material and energy consumption, the MicroPower is also absolutely cost-efficient. Another vital factor contributing to the MicroPower's cost-efficiency is the fact that the entire range of peripheral equipment is perfectly geared to the production of nano and micro parts. In this way, cost cuts of 30 to 50 % compared to standard machines can be achieved.
The modular machine system consists of a basic platform that can be extended according to customers' needs with a rotary disk, parts removal handling, integrated quality monitoring via image processing and a clean-room module, extendable up to a complete production cell. The clean room-compatible design and a clean room module which enable class 6 clean room environment according to ISO 14644-1 are optimal for medical applications. In this application, the parts are injected, tested and deposited in the clean room.
The special benefits of the MicroPower become obvious when processing extremely expensive bioresorbable plastic materials, such as are used in medical technology for clips, bone screws, bone plates, etc. These cost between 2000 and 5000 €/kg, so every 1/10 of a gram in material saved through a reduction in the amount of sprue underscores the equipment's great cost-efficiency. The material is also processed extremely gently to prevent unnecessary shearing.
At the MEDTEC, a medical clamp with a part weight of 0.003 g is manufactured from POM supplied by Ticona within a cycle time of 4 seconds on a MicroPower 15/7.5 with a 4-cavity mold from Microsystems UK. The parts are removed by a W8VS2 WITTMANN robot with a handling weight of 2 kg and passed on to a camera integrated in the production cell and in the machine's control system for quality inspection. The parts are subsequently separated according to cavities and stacked in a stacking module. In this application, the parts are injected, quality-inspected and stacked in a clean-room environment.
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