Thermoplastic Injection Molding

Thermoplastic Injection Molding, Insert Molding, and Over-Molding

With extensive molding capabilities, Excel has the necessary equipment and experience to bring your component designs to life. Excel works closely with trusted tool-making partners to develop tools that produce molded parts that consistently meet tight tolerances while minimizing scrap material to control costs. All injection molding operations are performed in a controlled environment, meeting or exceeding ISO 8 standards.

Molding Capabilities

The injection molding conducted at Excel employs state of the art, high precision all-electric injection molding machines and auxiliary equipment in a cleanroom environment. This high precision equipment lends Excel the ability to meet the tightest of tolerances above and beyond industry standards.

The components molded by Excel are assembled into finished medical devices used in a wide variety of fields of medicine from cardiology to dermatology. Excel molds all of the plastic components for its core line of hemostasis valves, as well as the customized hemostasis valves it manufactures for its customers.

Excel can produce injection molded parts from a number of thermoplastic raw materials. Excel has extensive experience in molding polycarbonate, copolyester, ABS, acrylic, and nylon among others. The experienced staff at Excel can help customers select the appropriate material for their molding project based on specific product requirements.

With extensive molding capabilities, Excel has the necessary equipment and experience to bring your component designs to life.

The Process of Component Development

The process for creating a new injection molded component begins with the design and development of a functional concept. A 3D CAD model is created to determine the form and fit for the particular function that the component is designed to serve. Excel can provide design for manufacturability input to customers in the design phases of their molding projects to ensure that the designed components can be reliably produced to specification.

Once a part is designed, prototypes are created to confirm that the part will function as intended. Excel provides responsive, same day in-house 3D printing services to assist customers with their proof of concept.

Excel works closely with a number of mold makers to design injection molds that will consistently and efficiently produce components that meet specification. Considerations such as parting lines, draft angles, and gate locations are determined during this phase.

Upon completion of a new mold, all components are then fully validated utilizing the industry standard IQ/OQ/PQ approach. An initial parameter profile is developed utilizing Scientific Injection Molding principles. Further refinement of the initial process occurs during execution of Designs of Experiment (DOE). Proposed process control limits are then challenged though the Operational Qualification (OQ) portion of the validation. A Performance Qualification (PQ) is then performed to prove out the stability of the process under actual production conditions.

With the validations complete, parts are ready to be run for full scale commercial production. Excel has the capacity to mold routine production components in low and high volumes.