Fast reaction for biochip testing

The fast-turnaround tooling project was a critical to the scheduled launch of Randox’s new Evidence Evolution product, claimed to be the world’s first fully automated, random access biochip testing platform, which is anticipated to revolutionise current diagnostic testing.

For the debut of this new technology, Randox developed a visually impressive instrument casing, incorporating a range of colours and finishes. Making the tools for this was quite a challenge as the largest moulding measures 1668mm by 1191mm by 403mm, and all parts were specified to be cast in fully certified UL94 V0 flame retardant material to allow for full internal shipping and the obtaining of necessary approvals.

Altogether, the equipment casing incorporated a total of 26 reaction injection moulded (RIM) components, as well as numerous smaller injection moulded parts – and naturally the budget needed to be carefully managed on such a large scale project.

During its 20 years of specialisation in the creation of RIM tooling, Midas has developed its own trademarked tooling processes, MRIMTM, which enables the company to produce highly complex mouldings with little or no compromise on detail, in relatively low volumes, and in a wide range of finishes. This, together with Midas’ guarantee of 5000-off shots per tool, provided Randox with the production solution it required.

Midas worked with the client as an integral part of the tooling development team for the project to make sure that all parts considered for RIM were appropriately designed for the process. This time spent at the early design phases eliminated issues which could have occurred later in tool manufacture. In the event, no modifications were required to any of the 26 parts produced – demonstrating the effectiveness of the design for manufacture process.

A combination of face-to-face meetings, conference calls and email dialogues supported the necessary project management, which was necessary due to the significant geographic distance between the different locations. Embracing modern communication techniques reduced internal costs to both parties and also streamlined the development phase when time to manufacture was so critical.

All the tooling was produced on time during the phased released programme, allowing the client to check and release parts in stages which matched the build phase and also helped spread the tooling start times. Good project management was essential due to the number of parts involved and ensured that any mid-process changes that occurred were well managed and integrated and that correct issue levels and part details were being produced.