TECHNOLOGY | MEDICAL MOULDING
increasingly requires production of small-volume batches, down to one-piece flow, which suits Arburg’s Freeformer additive manufacturing technology. “The Freeformer is in high demand for custom implants made of biocompatible, resorb- able, sterilisable and FDA-approved original materials, individual orthotics and models for surgery preparation,” says Manka. “Geometric freedom, combined with material freedom, enables the open system to achieve entirely new plastic applications – including for use within the human body. Droplet size and process control can be specifically influenced, resulting in individual customisation options.” Arburg also helps with the demands of unique device identification (UDI), which requires manufac- turers of medical devices to provide proof of complete batch traceability. He says: “The Arburg host computer system ALS ensures this shot-for- shot. Not only process parameters are being monitored, but also machine statuses and mainte- nance intervals.” The company has turned its attention to COP
and COC plastics, which were developed as glass substitutes in medical technology. With these plastics, the manufacturer’s instructions explicitly refer to processing with nitrogen as an inert gas to avoid black particles in the parts. In terms of process technology, nitrogen flushing first requires a gas extraction station on the injection moulding machine. Arburg has recently designed a compact unit with integrated flow measurement for All- rounders for this purpose. The desired nitrogen feed to the injection unit’s material feed zone can be easily adjusted via a pressure regulator. In production, only a gas connection with a maximum of 40 bar needs to be provided.
Above: Arburg’s Freeformer for additive manufactur- ing has a large potential for medical technology. The machine can be used in cleanrooms and processes FDA-approved original plastic materials
In mass production, efficient processes are key due to the high-cost pressures in the medical market. Arburg says that the hybrid and electric Allrounder Hidrive and Alldrive injection moulding machines, which are also available in a packaging version, are designed for efficient and high-quality series production and are ideal for mass produc- tion. They offer short cycle times, reproducibility and reduced energy requirements, as well as process stability and a long service life. They also have better emission ratings than hydraulic machines. There is also a rising demand for turnkey
projects in the field of medical technology. Inte- grating quality inspection and assembly equipment downstream of injection moulding is eliminating human intervention, which still represents the greatest potential for product contamination. The Freeformer and Arburg Plastics Freeforming
Above: Potential Freeformer applications include the individualisation of medication that could be optimised in terms of dosage, type of release and even combination of active substances
30 INJECTION WORLD | September 2021
(APF) are the company’s solution for the individual treatment of patients with precisely tailored medical products made of plastic. The range covers auxiliary products to medication or implants. Another process for medical applications is Liquid Additive Manufacturing (LAM). In the LAM process from InnovatiQ LSR, material can be 3D printed directly. This company has been a member of the Arburg group since February 2020. Arburg’s portfolio of injection moulding ma- chines also includes Allrounders for medical micro-injection moulding applications. Regardless of whether the application involves thermoplastics or elastomers, the company says that the solutions provide for maximum precision and reproducibility.
www.injectionworld.com
IMAGE: UNIVERSITY OF EAST ANGLIA
IMAGE: ARBURG
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