In large part, the future of medical injection molding in the United States depends on its ability to innovate in leading-edge mold manufacturing. Mold designers and manufacturers must respond to requirements for more cost-effective medical device components, high quality parts, and smaller parts, in addition to other trends.
One of the long-time leading players is Bill Kushmaul, who started Tech Mold in Tempe, AZ in partnership with Steve Uhlman, founder of Tech Plastics (eventually the Tech Group) in 1972. Initial targets included electronics and personal computer markets. Over time, the company began focusing on high-volume, high-cavitation molds for packaging (caps and closures, dispensers), the medical disposable industry and personal care/consumer markets.
Tech Mold is the mold maker of choice for two recent demonstrations in hot runner side gating for syringe molds. Mold-Masters developed Melt-Cube, a linear side gating system that allows 20% higher pitch density than circular systems and is designed for easy tip replacement in the press. Tech Mold built the mold for a demonstration at NPE2012 (April 1-5) in the CBW booth (#3169), where a 16-cavity automated system will be producing a 5-6cc polypropylene medical syringe with IML that integrates graphics with anti-piracy features. Tech Mold also supplied the mold for a Husky Injection Molding Systems demonstration of its Ultra SideGate hot runner at the Fakuma International Trade Fair in Germany last October. The mold was running polyoxymethylene (POM) resin producing a 0.5 gram medical cap with 1.25 millimeter wall thickness.
Plastics Today discussed the future of mold making for the medical market with Kushmaul on the eve of NPE2012 in Orlando, FL (April 1-5). He stresses that he comes from a perspective of a manufacturer of very high-cavitation molds for the medical disposable market, and that the medical market comprises many more opportunities for mold makers including lower cavitation molds for other types of medical devices, durable instrumentation, and other applications. Many opportunities are emerging, for example, in micro molded medical products, as reported by Plastics Today.
Twenty years ago Baxter closed its molding facility in Southern California and put all the work into the Tech Group's medical molding facility. The cycle for this activity tends to be about five years on the short cycle end and 20 years in the long cycle for companies to alter their business model with respect to whether they 'make or buy.' It's a 'make or buy' wheel. The medical OEM has its own molding operation because they feel it gives them control, so they invest in state-of-the-art molding machines and in-house molding. Then they realize that they're giving their molding operations free rent in their facility, and that they'd rather invest in their medical business - designing new products, marketing and selling their products, and that manufacturing takes a lot of resources they'd rather put other places.
So they go to the custom molders, which means buyers get involved and their job is to buy cheaper and cheaper, and ultimately tooling becomes the realm of the custom molder, and the mold maker is left dealing with people at the OEM who might not have engineering expertise to understand the role of the mold maker in the overall success of the product.
Today's trend is to outsource moldmaking from the OEM. However, the OEM is placing more and greater demands on the moldmaker for tighter dimensions and features, with minimal costs.
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