Injection molding processes, including insert molding, overmolding, and micro-molding for specialty polymers require experience, expertise, and specialty equipment. Micromolding in particular requires precision to ensure specific geometries are not only achievable but repeatable at scale.
Custom Medical Molding
Our East Providence facility specializes in custom plastic components for medical applications which require injection molding processes including, micromolding, insert molding, or overmolding. We work to highly complex tolerances and quality standards to ensure that the part you need is formed with precision, using state-of-the-art automation, vision systems, and cleanroom production to name a few.
Our moldings and micromolding are found in any number of medical applications including, drug delivery systems, implantable components, bioresorbable sutures, and more.
To send us your specs, 3-D printed sample, or customize a part from the ground up, request a quote.
Bioresorbable Resins Molding
We have established a core competency in tooling and processing bioresorbable resins designed to be implanted and absorbed within the body, like bioresorbable stents and other dissolvable medical components. We work with a variety of PLA, PLA/PGA blends, and PHB resins with varying intrinsic viscosity (IV) values provided by the major suppliers. Our proprietary test mold optimizes the mold design process by testing gate size and geometry. Combined with MoldFlow® analysis and Design of Experiment (DOE) practices, this proven approach promotes successful technical and commercial outcomes.
Some of the bioresorbable materials we work with include:
High Temperature Resins Molding
While we often mold or insert molds products from nylons, polycarbonates, acetals, thermoplastic polyesters, and ABS resins (all of which are unfilled and fiberglass-reinforced), we specialize in producing parts from high-temperature resistant resins, both unfilled and reinforced.
Among the high-temperature thermoplastics we mold:
- Liquid crystal polymers (LCP), both fiberglass and carbon reinforced
- Polyarylsulfone (PAS)
- Polyetheretherketone (PEEK)
- Polyetherimide (PEI), both unfilled and reinforced
- Polyethersulfone (PES), both unfilled and reinforced
- Polyphenylene sulfide (PPS), fiberglass reinforced
Microfluidics Molding & Microfluidics Devices
We have exceptional capability in the area of ultra-precision molding of microstructures for in vitro diagnostics and life science consumables. Our molding capabilities include a variety of these types of applications using COP, COC, PMMA, PP, and PC resins in a cleanroom environment. We’ll assist you in converting your existing glass or silicon chip with related microstructures to plastic by replicating the tooling for plastic part fabrication. We also offer clear microscope slides on a 75mm x 25mm x 1mm standard platform.
Elastomer Injection Molding
High precision capabilities also include the injection molding of elastomeric materials. Whether serving the medical, electronic, or consumer industries, our highly developed injection molding processes are geared towards high precision and repeatability in often difficult to process elastomeric materials. Challenges in elastomeric injection molding such as gate vestige control are met head-on with unique, highly engineered solutions.
Elastomers Injection Molding Services
Injection molding elastomers we process include:
Additional infrastructure and talent attributes include:
- Class 8 cleanroom production
- State of the art metrology, capable of measuring at the sub-micron level
- Scientific molding practices
- IQ/OQ/PQ protocols
- Established material testing capabilities
- Tooling designs that promote efficient material consumption