examples of how plastic CNC machining prototypes have improved the
development of specific medical devices
Surgical Instruments: Prototypes created through plastic CNC
machining are instrumental in the development and refinement of
surgical tools, including laparoscopic and orthopedic instruments.
These prototypes, which closely match the final products, enable
designers and surgeons to evaluate the ergonomics, functionality,
and user-friendliness of the instruments. The iterative design
process ensures the instruments are optimized for precision and
efficiency in surgical procedures.
Prosthetic Limbs: In the realm of prosthetic limb development,
plastic CNC machining prototypes are crucial. Manufacturers use
these prototypes, tailored to individual patient measurements and
designs, to produce functional limbs that replicate the final
product. This allows for the adjustment and testing of fit,
alignment, and motion range, culminating in prosthetic limbs that
provide enhanced comfort, mobility, and functionality to users.
Plastic CNC machining prototypes are vital in developing housings
and enclosures for medical devices. They allow designers to assess
the fit, finish, and aesthetic appeal. Moreover, they provide an
opportunity to test the placement and accessibility of buttons,
switches, and interfaces, crucial for intuitive and user-friendly
designs. Through ongoing refinement, manufacturers can create
devices that not only function well but are also visually appealing
and easy to use.
Diagnostic Equipment Components: Prototypes produced via plastic
CNC machining play a pivotal role in the development of parts for
diagnostic devices such as MRI and ultrasound machines. These
prototypes are vital for evaluating the functionality and accuracy
of different components, including sensor housings, probe
connectors, and patient interfaces. Prototype validation enables
manufacturers to improve the accuracy, reliability, and quality of
the diagnostic equipment.
Drug Delivery Devices: Plastic CNC machining prototypes have been
used to refine drug delivery devices, such as inhalers or injection
pens. Prototypes allow for the evaluation of factors like
ergonomics, ease of use, and dose accuracy. By incorporating user
feedback and conducting usability studies with prototypes,
manufacturers can optimize the design and functionality of these
devices, ensuring effective and convenient drug delivery for
patients.
The examples illustrate the crucial role of plastic CNC machining
prototypes in advancing the development of diverse medical devices.
They facilitate iterative design enhancements, functional testing,
the integration of user feedback, and the overall improvement of
device functionality and user-friendliness.
| Materials for Vacuum Casting |
You can choose a wide range of vacuum casting materials depending
on the peculiarities of your project.
Here are some choices for you: |
| Process | Description |
| Step 1. Master Pattern Creation | The procedure starts with the development of a master pattern,
which acts as the prototype for duplication. This master pattern
can be crafted through several techniques, including 3D printing,
CNC machining, or conventional manufacturing methods. |
| Step 2. Mold Preparation | A silicone mold is formed around the master pattern, usually in two
halves, to facilitate the easy removal of the pattern and
subsequent casting. Once created, the mold is secured inside a
casting frame. |
| Step 3. Mold Release and Preparation | Prior to casting, a mold release agent is applied to ensure the
easy removal of the final casted part from the mold. The mold is
then preheated to a specific temperature to enhance material flow
and reduce curing time. |
| Step 4. Material Mixing and Vacuum Degassing | The selected casting material, typically a two-part polyurethane
(PU) resin, is mixed thoroughly to ensure uniform consistency. Once
mixed, the material is placed in a vacuum chamber to eliminate any
air bubbles or voids that might compromise the quality of the final
product. |
| Step 5. Casting Process | Polycarbonate (PC) is a type of amorphous thermoplastic celebrated
for its outstanding transparency and impact resistance.
Additionally, it has robust electrical insulation properties and a
moderate level of chemical resistance. |
| Step 6. Curing and Solidification | Once the mold is filled, the casting remains undisturbed to cure
and harden. The duration of curing depends on the type of resin,
the thickness of the part, and the surrounding conditions. If
needed, heat or additional post-curing can be used to expedite the
curing process. |
| Step 7. Mold Opening and Part Extraction | After the resin solidifies, the mold is opened, and the cast
component is gently extracted. The mold can be repeatedly used to
create more parts. |
| Step 8. Finishing and surface treatment | To attain the required aesthetics and functionality, the cast part
may necessitate finishing and surface treatments, including
trimming off excess material, sanding, painting, or applying other
surface enhancements. |
Our firm provides a wide array of professional finishing services
that improve the look, functionality, and longevity of components.
The key finishing services we offer include:
Anodizing: This electrochemical procedure, mainly applied to
aluminum parts, forms a protective oxide coating that enhances
corrosion resistance and offers a decorative appearance.
Additionally, anodizing can be paired with dyeing to introduce
various color choices.
Painting: Our painting services enable the application of diverse
paint types to attain the preferred colors, textures, or protective
coatings. Methods such as spray painting and powder coating are
frequently utilized to improve the aesthetic and surface properties
of components.
Pad and Silk Screen Printing: These techniques are utilized to
apply bespoke designs, logos, or labels onto various parts. They
serve to promote branding, product identification, and the
inclusion of instructional information, thereby augmenting the
aesthetic appeal.
Sanding and Polishing: Our services employ abrasive materials to
smooth out roughness and imperfections on surfaces, achieving a
finer and more polished finish. This method not only improves the
parts' appearance but also their tactile quality.
Vapor Polishing: This process involves using solvents or chemicals
to smooth the surface of plastic parts, removing imperfections and
yielding a shiny, clear finish. Vapor polishing improves the
aesthetic and functional quality of plastic components.
Powder Coating: This is a dry finishing technique in which a fine
powder is electrostatically charged and applied to a part's
surface. After application, the part is heated, causing the powder
to melt and solidify into a tough, protective coating. Powder
coating offers superior resistance to corrosion, chemicals, and
ultraviolet radiation.
Blasting refers to the process of propelling high-velocity
particles or beads at the surface of components. This method
efficiently eliminates imperfections, burrs, and sharp edges,
achieving a uniform and matte surface finish. Blasting enhances the
overall surface condition and readies the components for further
treatments or uses.
By taking advantage of our comprehensive finishing services, you
can be confident that your parts will not only fulfill functional
specifications but will also exhibit an improved appearance,
enhanced performance, and greater longevity. Our experienced team
will collaborate with you to identify the finishing techniques that
best align with your unique needs.
Inspections and Review for Every Stage of Production
Barana Rapid ensures quality throughout the entire process by
offering these inspection and review services:
Thorough verification of incoming materials
Design for manufacturing assessments for all provided quotes
Contract evaluations upon purchase order receipt
First article and ongoing process inspections
Comprehensive final inspections and tests, complete with necessary
reports and certifications
