skip to Main Content
Designing Small, Complex Medical Part Molds

Designing Small, Complex Medical Part Molds

A mold maker producing tools for thermoplastic materials and die-castings uses Hexagon Manufacturing Intelligence VISI Analysis module—a mold tool design solution, to discover critical areas at an early stage of the design process, which simplifies their work.

The company, Mecca T.P. which serves a variety of industry sectors, such as medical and automotive, produces between 40 and 80 molds a year using a variety of molding metals. Co-owner Antonio Tognon said their molds have to be produced swiftly and accurately, first time every time, without the need for changing them unless requested by the customer. And in those cases, the amendments have to be carried out quickly.

VISI Mold is used to carry out the design of molds, while electrodes are modelled and machined with VISI Machining 3D, which is also used for cutting plates and molding parts, along with Machining Strategist and VISI Wire.

“Our in-house team follows the mold design, adopting various solutions for mold movements, conditioning circuits, injection and extraction systems,” Tognon said. “In order to optimise the final product and the molding activity, we pay precise attention to the analysis, proposing possible improvements.”

Used in the preliminary stage, before the design process begins, VISI mold is used to analyse details such as drafts, undercuts and thicknesses, and to draw up possible dimensions of the finished molds. “We import customer STEP, IGES or Parasolid files and analyse the geometry in depth, to define the quality of the mathematical model, while correcting incomplete or inaccurate geometries.”

They move on to create the mold basement and define details, before sending the component parts to the different CAM stations for milling, wire cutting, and electrode modelling and construction.

The company has developed a stainless steel mold to replace an existing mold used by a medical sector client. “The mold was to produce a small circular component with a diameter of approximately 40 mm. The part had to be molded in a white chamber on eight impressions, in a complete discharge cycle of less than 20 seconds.” The product is described as being complex, with irregular surfaces and a different front and back finish, and a shiny, mirrored surface on one side.

“Our proposal optimised the intrinsic characteristics of the impressions, and the operational flexibility, ensuring the highest level of productivity. Each imprint has a completely interchangeable matrix and punch, which are fixed to the mold by screws. This means we can replace them when they are worn out, without changing the entire mold, even if the mold is inside the machine. It also means we can produce different products using the same mold.”

The main challenge was to find a way to free undercuts; also, to create the movements necessary to obtain a high-quality piece—molded from soft adhesive PVC – in the correct way, avoiding possible wastage.

The VISI Mold handled the design process and provided them with specific automation that guided the operator throughout the project’s development. Thus, this optimised the process from design to delivery, which allows compliance with increasingly tight delivery times.

 

FOLLOW US ON: LinkedIn, Facebook, Twitter

READ MORE IN OUR LATEST ISSUE

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

 

3D Goes Long-Range With The First Scanning Laser Tracker

3D Goes Long-Range With The First Scanning Laser Tracker

Hexagon’s Manufacturing Intelligence division has launched a laser tracker line, the Leica Absolute Tracker ATS600. This new product introduces a new concept in metrology-grade laser trackers, with targetless 3D scanning possible for the first time, directly from the laser tracker. The ATS600 can scan a surface with metrological accuracy from a distance of up to 60 metres with no need for targets, sprays, reflectors or probes.

Following in the footsteps of the Leica Absolute Scanner LAS-XL that was released in 2017, the ATS600 delivers as much accuracy as is needed by targeted metrology applications, with its focus more on measurement usability and processing speed. Previously difficult to reach areas are simply measured without even the need for tracker repositioning, while surfaces that would previously have taken hours to manually scan can now be digitised in minutes.

“We’re always very focused on usability and productivity throughout our research and development process, and so large-scale scanning is a very interesting concept for us,” said Matthias Saure, Laser Tracker Product Manager at Hexagon. “Like the LAS-XL before it, the ATS600 introduces a fundamental change to the scale in which we think about non-contact scanning. We know that users are increasingly interested in digitising parts as a way to absolutely ensure production quality, and we think the ATS600 is a product that can really take digitisation into new places of industrial production and play a key role in expanding the role of quality assurance.”

The system works by identifying a scan area within its field of view and then creating a sequentially measured grid of data points that define that surface, with accuracy to within as little as 300 microns. Measurement point density is fully customisable, so that users can choose the ideal balance between detail and process speed for their specific application. The Leica Absolute Tracker ATS600 is unique in delivering this functionality at metrology-grade accuracy and alongside easy integration within established metrology workflows – the ATS600 is compatible with all major metrology software platforms as has been designed to sit comfortably within a wider metrology toolkit.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

Hexagon Launches Fixed-Line Blue Laser Scanning Sensor

Hexagon Launches Fixed-Line Blue Laser Scanning Sensor

Hexagon’s Manufacturing Intelligence division has launched its first blue laser scanning sensor for creating point clouds. The HP-L-5.8 joins Hexagon’s comprehensive range of tactile and non-contact sensors for CMMs and is designed for companies who need a versatile, affordable, fixed-line laser sensor.

The HP-L-5.8 performs equally well when taking point cloud measurements from dark or shiny surfaces. Designed to be rugged and compact, it protects the sensor from collisions and vibrations and is ideal for use in areas where accessibility is restricted as well as on smaller CMMs.

“Increasingly our customers want to add the speed and wide measurement coverage of laser scanning to their CMM’s capabilities,” says Christian Schorr, Hexagon’s Product Manager for Laser Scanners on CMMs. “The HP-L-5.8 meets our customers’ demand for an accurate, affordable laser scanner that turns a CMM into a multisensor machine that can switch easily between tactile probing or laser scanning in a single part program.”

The HP-L-5.8 is seamlessly compatible with Hexagon CMMs that use PC-DMIS 2018 R2 and subsequent versions of the software and works with an automatic indexing probe head or continuous wrist, making it easy to operate for users of tactile probing tools.

The HP-L-5.8 is available worldwide.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

Back To Top