MEDICAL MOULDING | TECHNOLOGY
customers get to market quicker, as well as increasing yield by reducing scrap rates. Husky adds that UltraShot also eliminates subsequent manufacturing steps and enables new part designs and new resin usage – parts can be manufactured based on function and not injection moulding limitations. The company says that UltraShot allows for perfect melt management and cavity filling, which is key to final part quality and overall equipment efficiency. With the UltraShot, Husky has moved the shooting pots in close proximity to the gate, allowing for greater, highly precise moulding control. The UltraShot Injection System pressurises the resin near the cavities, reducing the influence of resin compressibility and shear, and thermal variations on balance and part quality. Eliminating these influences, the UltraShot Injection System achieves optimal balance and good part quality. The discrete injection circuit design is scalable to 128 cavities, providing the same process conditions regardless of mould size. Elimination of the scaling effects leads to faster qualification time from pilot to product tooling while reducing risk. Compared to conven- tional hot runners, melt in the UltraShot Injection System experi- ences fewer high-pressure injection cycles, preserving the original resin properties. This leads to lower moulded-in stress and better mechanical and optical properties in the moulded part. According to Husky, the Ultra- Shot technology enables moulders to design for part function instead of being limited by process capabilities, which leads to a higher quality and finer products. Now product designs can be further optimised for function enabling new quality and safety standards. In addition, connecting innovation with risk reduction, the UltraShot offers repeatability with pressure monitoring and traceability, so any issues are traceable and caught in real time. This virtually eliminates the ‘high-risk’ scenario, says Husky. In a recent project, UltraShot was used to develop a medical diagnostic tool in a high-pres- sure mould. The objective was to increase produc- tion to 80m parts per year. Process limitations included four cavity tools with up to 8% scrap rate, a narrow process window that was unstable due to high pressures, and a high temperature and corrosive resin. The UltraShot solution involved an
www.injectionworld.com
eight-cavity tool producing three different parts each cycle. Compared with a conventional hot runner system, UltraShot allowed a reduction in mould pressure from 2,500 to 1,200 bar, and a reduction from a 14 shot to 9 shot moulding cycle
with melt temperature reduced from 440℃ to 375℃. A 60% reduction in part cost was achieved. Husky adds that risk can also be minimised by
eliminating artificial boundaries that are created by integrating different subcomponents, such as a mould, hot runner or a machine, into a production cell. “We are leveraging its capabilities in injection moulding systems, together with the historical expertise of the Schöttli brand for medical tooling to completely re-design and bring to market fully integrated medical injection systems,” says Ellis. “The latest result in this direction is the development of a new platform – ICHOR – for the produc- tion of blood collection tubes, which combines the performance of a high output system, with the accuracy and quality requirements of the medical market.”
He says: “The system, which will be launched by the end of 2021, integrates mould, hot runner, injection moulding machine and auxiliaries, making it the first integrat- ed one-stop solution. Additionally, the production capabilities will be maintained through the entire lifecycle through Advantage + Elite, Husky’s unique remote monitoring and proactive service solution. Advantage + Elite allows full visibility and traceability of all key equipment and process variables and parameters.
Preliminary tests indicate a cycle time performance equal to or below 5.8 s on a 48-cavity system. This is on a platform that will be able to accommodate moulds from 32 up to 72 cavities, before moving to a larger machine platform.”
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.sumitomo-shi-demag.eu �
www.basf.com �
www.avenuemouldsolutions.ie �
www.arburg.com �
www.wittmann-group.com �
www.engelglobal.com �
www.ach-solution.at �
www.tanner-formenbau.ch �
www.husky.co https://www.husky.co/en/solutions/hot-runners/ultrashot/ �
www.benvic.com
September 2021 | INJECTION WORLD 35
Left: Husky has developed UltraShot hot runner
technology, which offers a number of important
advantages for the medical market
IMAGE: HUSKY
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56
