Pressure forming close-tolerance parts for mobile mammography device

How Profile helped successfully launch new medical diagnostic equipment

Pressure Forming Replaces Injection Molding

Mobile mammography and biopsy equipment makes it easier for healthcare providers to screen patients for breast cancer. Wheeled carts need to be able to roll easily along floors but also be durable to resist impact with doors and walls.

A medical device manufacturer approached Profile Plastics to thermoform cover panels for their latest mammography machine. The OEM required plastic panels to safely cover a portable power unit, provide aesthetic appeal, and resist contact with harsh cleaning chemicals.

Challenge: How do you move away from injection molding?

Total project cost is tied to volume and can make the difference for a successful commercial launch. When high part volumes (like consumer products) are produced, tooling costs are easier to absorb. OEM projects like medical devices usually have low to mid volumes and are more sensitive to the cost of tools.

This medical company needed nine covers for their portable equipment. Previously, the design team only had experience with injection molded plastic parts. That process could provide lightweight, close-tolerance parts with high chemical resistance. However, the tooling costs were prohibitively expensive for limited annual quantities.

Finding an alternative that could meet the application requirements became a priority. Product managers received a recommendation to try pressure forming with Profile Plastics. Pressure forming offered lower-cost tooling and more design freedom, including support for undercuts, design elements that help parts fit together and close securely. However, the parts would need some redesign for the new process.

Learn more about how pressure forming compares to injection molding.

Solution: Partner with a thermoformer with DFM and materials expertise

Profile offers Design for Manufacturing (DFM) assistance. Their team worked closely with the OEM’s engineers to develop part drawings that could take full advantage of the pressure forming process. Adding effective undercuts to the design improved ease of manufacturing.

The added value didn’t end there. Engineers recommended KYDEX® T brand PVC/Acrylic blend thermoplastic. This lightweight thermoplastic features high resistance to impact, chemicals, and staining. It also offers low heat distortion, so covers can handle the heat from portable power units.

White was also available as a standard color in this material, saving cost compared to custom colors. Because it suggests cleanliness, white is common in healthcare applications.

Results: Close-Tolerance Parts That Look Great and Cost Less

In the end, Profile produced nine pressure-formed covers with close tolerances and expert undercuts. The parts looked great, providing the aesthetic appeal and durability the medical OEM required. And the project cost significantly less than using injection molded parts.