Company insight
Precision, persistence and disruption
Accumold has achieved a world-first in high-volume thin-walled cannula production, overcoming the precision, scalability and reliability challenges that have long limited conventional manufacturing methods. Its proprietary micro-injection moulding process is transforming performance, costs and possibilities for medical device innovators in fields from wearable diabetes management to advanced surgical tools.
ccumold has redefined what’s possible in thin-walled cannula production – critical components in devices such as wearable diabetes management systems, ophthalmic instruments and advanced drug delivery technologies. After five years of innovation and engineering mastery, Accumold has perfected a proprietary micro-injection moulding process that enables high-volume manufacture of these intricate, ultra- precise parts. This breakthrough eliminates the shortcomings of traditional methods such as extrusion, tipping and gluing, unlocking new levels of performance, cost-efficiency and scalability.
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costs, slow production and create potential failure points, as adhesives can degrade and components loosen. Meeting high- volume demand while maintaining precision has long been a challenge.
A breakthrough approach Accumold’s process replaces multiple steps with a single, streamlined micro moulding operation. Moulding the cannula directly produces a stronger, more reliable part straight from the mould, with no glued joints or secondary forming. Fully automated, proprietary micro moulding presses and precision-engineered multi- cavity tools now allow production of up to
“Accumold’s process lowers costs, accelerates timelines and makes large-scale manufacturing commercially viable.”
Why thin-walled cannulas matter Thin-walled cannulas are essential in modern medicine. In wearable diabetes devices they deliver life-sustaining insulin with minimal discomfort, helping patients manage their condition with confidence. In surgical applications, their delicate profiles reduce tissue disruption, speed recovery and enable precision procedures in hard- to-reach anatomical areas. As devices shrink and procedures become less invasive, demand for these components continues to grow.
The limitations of traditional production Historically, thin-walled cannulas have been made via extrusion – a process prone to irregular wall thickness, defects and high fallout rates. Secondary steps such as tipping and gluing metal hubs increase
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40 million cannulas per year from a single cell, each with tolerances as fine as 0.0006in.
Keys to success
Perfecting this capability required mastery of materials, design and equipment. Material choice was crucial: polycarbonate was selected for ophthalmic cannulas needing rigidity, while polypropylene was ideal for drug delivery applications requiring patient comfort.
Design precision was equally important. Uniform wall thickness, optimal gate placement, effective venting and carefully managed aspect ratios ensured flawless cavity filling, structural integrity and consistent quality. During development, Accumold found that conventional moulding presses could not meet these demands, struggling with non-fill and flash. The solution was to rely on in-house-
developed presses, refined over decades for ultra-precise, high-volume production.
Transforming performance and market potential For manufacturers, the benefits are profound. By removing secondary steps and reducing failure points, Accumold’s process lowers costs, accelerates timelines and makes large-scale manufacturing commercially viable. For patients, it means more reliable devices, greater comfort and confidence in their treatment. While wearable diabetes devices have been a primary focus, applications extend far beyond. Oncology drug delivery systems, microfluidic biotech devices, aerospace fluid management systems and next-generation surgical tools can all benefit from this capability. Any application requiring ultra- thin, high-precision tubular components now has a more reliable, scalable and cost- effective path to production.
A vision for the future
This achievement is more than a milestone; it reflects Accumold’s commitment to challenging conventional manufacturing and pushing the boundaries of micro moulding. The company continues to explore opportunities to replace multi-step manual processes with automated, scalable moulding solutions. With a 130,000ft², ISO 13485-certified facility operating 24/7, a team of over 350 specialists and the proven ability to deliver tens of millions of precision parts annually worldwide, Accumold is ideally positioned to help medical OEMs bring ambitious concepts to life. The era of compromise in thin-walled cannula manufacturing is over. Accumold has made sure of it. ●
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