Company insight
Wearables and the critical role of micro moulding
Micro moulding plays a key role in the miniaturisation of wearable devices such as continuous glucose monitors (CGMs), insulin pumps, and smartwatches, which have revolutionised personal health management. This specialised manufacturing technique enables the production of ultra- small, thin, and intricate components with precise dimensions, essential for the compact designs of modern wearables. Micro moulding specialist Accumold discusses how it enhances functionality, reliability, and comfort, contributing to more user-friendly and effective devices.
s demand for personalised healthcare and lifestyle technology grows, micro moulding is driving innovation by supporting the miniaturisation of devices and integrating advanced materials and multifunctional components. This allows manufacturers to explore new design possibilities and push beyond traditional manufacturing limitations. With micro moulding, wearable devices are becoming smaller, smarter, and more efficient. One significant advantage of micro moulding is its ability to produce extremely thin parts, which is vital for the compactness, comfort, and functionality of wearable devices. Thinner components reduce the size and weight of devices, enhancing user comfort and encouraging continuous use — especially important for devices like CGMs and insulin pumps that are worn throughout the day.
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Thin components also allow for more flexible designs. Ultra-thin parts can be integrated into flexible circuits that conform to the body, improving comfort and durability. Additionally, they enable the inclusion of advanced features, such as microfluidic channels, sensors, or electronic circuits, within limited space. This adaptability is crucial as wearables evolve in both design and functionality. Micro moulding contributes to the aesthetic appeal of wearables, producing sleek, lightweight designs that are more comfortable and appealing to consumers. By allowing for discreet and stylish devices, micro moulding meets consumer expectations for both form and function, helping drive wearable technology’s success.
and collaboration with suppliers to develop suitable polymers and composites. Advanced simulation software helps predict and prevent potential moulding issues. Mould design and fabrication for ultra-thin components demand incredible precision, with features often measured in microns. Moulds must be carefully engineered, with split lines and venting strategies adapted to ensure the final component’s integrity. Effective venting, for example, allows air and gases to escape during the injection process, preventing defects such as voids.
Micro moulding enables ultra-thin, advanced components for smarter wearables.
However, the demand for thinner components presents challenges for the micro moulding process. Precision and tolerance control are critical, as even minor dimensional deviations can lead to functional failures or assembly issues. Maintaining precision requires advanced moulding techniques and cutting-edge machinery. Expert companies like Accumould use state-of-the-art and proprietary equipment to produce components with micro-scale accuracy, ensuring all parts meet specifications.
Innovative materials and processes Material selection is also crucial for ultra-thin applications. Thin components require materials that can consistently fill the mould cavity without defects such as warping or incomplete fills. This requires expertise in material science
Medical Device Developments /
www.nsmedicaldevices.com
Process optimisation and quality control are essential to maintaining consistent production. Micro moulding processes must be monitored to avoid defects from temperature, pressure, or material variations. Advanced quality control techniques, including in-line inspection and metrology, ensure that each part meets required specifications. Continuous innovation is critical as the demand for thinner components pushes companies like Accumould to explore new materials, technologies, and methodologies. This commitment to innovation enables them to meet the evolving needs of the market and deliver high-performing, reliable wearable devices.
Micro moulding is essential for advancing wearable technology by enabling the creation of ultra-thin, complex components that enhance functionality, reliability, and comfort. As wearables evolve, micro moulding will remain central to the next generation of smaller, smarter, and more efficient devices. ●
www.accu-mold.com 33
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