Precision and Performance with Electronic Injection Molding and a Skilled Mold Maker
Medical devices require top-quality parts. Every plastic housing must meet strict standards. It must protect sensitive components, resist chemicals, and be easy to clean. When a medical company approached us to build a mold for their device’s plastic housing, we knew we had to deliver perfection. As an experienced Mold Maker with deep knowledge of Electronic Injection Molding, we were ready for the challenge.
This article shows the full process—step by step—of how we designed and made the medical housing mold. From the client’s 3D file to final mass production, we combined smart engineering, great communication, and modern mold-making tools.
Step 1: Understanding the Product
The customer was developing a new handheld diagnostic device. It would be used in hospitals, so the plastic housing had to meet strict rules:
- It must be strong but lightweight.
- It needed smooth, clean surfaces.
- It must withstand daily cleaning with alcohol-based chemicals.
- The design must include a snap-fit for easy assembly.
- The housing had to hold the PCB securely.
The client gave us a 3D CAD file and asked us to review it. As a professional Mold Maker, our job was not just to build a mold. We needed to make sure the part could be molded well using Electronic Injection Molding.
Step 2: Design Review and Feedback
We began by checking the 3D model. Our engineers found several issues:
- Wall thickness varied too much.
- No draft angles were present.
- Some corners were too sharp, which could trap plastic or cause stress marks.
- Snap-fit features were weak and could break.
- The parting line placement was not ideal.
We shared a detailed review with the customer. With their approval, we made design changes:
- We adjusted walls to be uniform at 2.5 mm.
- We added 2° draft to vertical walls.
- We rounded corners to improve flow.
- We strengthened snap-fits.
- We shifted the parting line to a flatter surface.
This helped prepare the part for smooth Electronic Injection Molding and easier mold ejection.
Step 3: Material Selection
The customer needed a material with good mechanical strength and chemical resistance. Working with them, we selected PC (polycarbonate) with medical-grade certification.
Polycarbonate is a great fit for Electronic Injection Molding because:
- It is clear and can be colored easily.
- It has excellent toughness.
- It resists impact and scratches.
- It is stable in heat and moisture.
- It tolerates alcohol and disinfectants.
As a reliable Mold Maker, we also ensured this material was easy to source and certified for medical use.
Step 4: Mold Design
With the final part design and material confirmed, we started designing the mold.
Key mold features included:
- A two-cavity mold to speed up production.
- A cold runner system for low-cost startup.
- Precision inserts to hold tight tolerances.
- Ejector pins placed away from cosmetic areas.
- Fine venting to avoid burn marks on snap features.
- Polished steel surfaces for a glossy part finish.
As a leading Mold Maker, we used top-grade mold steel. For this project, we selected H13 tool steel, which offers hardness, wear resistance, and long mold life—perfect for Electronic Injection Molding of medical parts.
Step 5: Mold Manufacturing
Once the mold design was approved, we moved to mold fabrication. We used high-speed CNC milling, EDM (electrical discharge machining), and hand polishing.
As a trusted Mold Maker, we followed strict steps:
- CNC machined all mold bases and inserts.
- EDM cut sharp internal corners.
- Polished cavity surfaces to achieve Class A finish.
- Installed cooling lines to control mold temperature.
- Built ejector and alignment systems.
- Assembled and tested all moving parts.
We completed the mold in 4 weeks and began mold trials right away.
Step 6: Mold Trials and Adjustments
The first mold trial used clear PC and matched our expectations well. But small changes were needed:
- One ejector pin left a slight mark.
- A snap-fit area had short fill.
- Cooling in one area caused warping.
Our Mold Maker team quickly adjusted pin placement, widened the gate, and improved water channeling. After these updates, the second mold trial showed perfect results. Part filling was even, ejection was smooth, and surface finish was excellent.
Step 7: Full Production with Electronic Injection Molding
With the mold approved, we moved to full production. Our Electronic Injection Molding machines were set up for this exact part.
We programmed:
- Barrel temperature: 270°C
- Mold temperature: 80°C
- Injection speed: medium
- Cooling time: 15 seconds
We also added inline quality checks. Every 50 parts, we inspected:
- Dimensions with calipers and gauges
- Surface finish under bright light
- Snap-fit strength by hand
- Warpage using a flat fixture
Over 10,000 units were molded in the first production batch. Scrap rate was below 0.4%. The customer was pleased with the results and asked for two more housing variations.
This project shows how good planning, smart design, and the skills of a real Mold Maker can make a difference in Electronic Injection Molding.
The plastic housing we created passed strict tests. It looked good, fit perfectly, and could handle tough hospital use. Every step—from CAD file to final mold—was handled with care and precision.
Choosing a reliable Mold Maker for Electronic Injection Molding is the key to success, especially in medical device projects. It ensures that your part is not only moldable, but high-quality, clean, and safe.