Paul Runyan, VP of sales, Accumold
In today’s ever-evolving technological landscape, the demand for precision-engineered micromoulded parts has skyrocketed. From medical devices to electronics, industries seek microparts that are consistent in quality and can be produced in large volumes. However, with the growth in demand, there’s a parallel increase in micromoulding companies, making the selection process for customers quite challenging. To ensure you’re partnering with a company proficient in delivering volume and repeatability, here are some essential questions you need to ask.
What is your experience in micromoulding?
Micromoulding transcends the simple notion of miniaturisation. It embodies the art of achieving impeccable precision and navigating the inherent complexities of creating minute components. A company seasoned in this field will inherently possess a deep-rooted understanding of the nuanced challenges and subtleties that the micromoulding process presents, ensuring it produces components that meet the highest standards of quality and functionality.
Core assets to look for are an integrated tooling department (does it manufacture its own tools?); experience with the micromoulding press of its choice (does it have the right equipment and experience level to operate the technology?); and thirdly, the quality equipment and know-how to prove the microcomponent is in specification (can it prove capability in production and hold the micro tolerances on the print?) These are the three key aspects of traditional micromoulding, so any lack of confidence in these areas may cause problems at the commercialisation stage of a project.
What materials do you specialise in, and what are their shrinkage rates?
Material shrinkage during moulding varies depending on the specific material used. Grasping these differential shrinkage rates is fundamental in the manufacturing process, as they directly impact the dimensional precision of the final product. The divergence in shrinkage rates poses a significant challenge for manufacturers, especially in the realm of micromoulding where precision is paramount.
Accurately predicting and understanding these rates is not just a matter of technical knowledge; it’s a prerequisite for achieving the desired dimensions and tolerances in the final product. A slight deviation, even in the micrometre range, can render a part useless or incompatible for its intended application. Therefore, a deep comprehension of material-specific shrinkage rates is a cornerstone of ensuring that the final micromoulded product is dimensionally accurate, is fit for purpose and meets the rigorous standards of quality and precision.
An innate understanding and experience of working with as big a library of thermoplastic resins as possible is vital for a micromoulding company to offer an optimal service. This experience means that the company is able to ask you the right questions to ensure the correct material is used. For example, what environmental conditions will the part need to operate under? Does it need to withstand solder reflow temperatures or other high-heat situations? Does it touch the human body or other biomaterials? Are there lubricity or hydroscopic properties to include or exclude?
Can you provide references or case studies from previous projects?
Assessing a micromoulding company’s track record offers invaluable insights into its proficiency and reliability. Historically, the way a company has executed its projects can often serve as a trustworthy predictor of its ability to deliver in the future. By scrutinising its past endeavours, one can ascertain the company’s expertise and aptitude in managing comparable tasks, allowing for an informed decision-making process when selecting a potential partner or vendor for new micromoulding projects. Most micromoulding companies will publish white papers on their website and many will have examples of prior legacy parts that show the microscale and tight tolerances on their website.
Ask your shortlisted micromoulding companies whether they can get close to meeting the following criteria:
- ability to produce parts up to 13 mm (0.5 in.) in the largest dimension;
- ability to produce small parts around 800 (0.031) x 300 (0.012) x 380 µm (0.015 in.);
- ability to create thin wall sections near 0.1 mm (0.004 in.);
- ability to achieve feature aspect ratios of around 6:1;
- ability to achieve part volumes 0.08 cm3 (0.005 in.3) or less;
- ability to create gate sizes as small as 0.1 mm (0.004 in.);
- ability to create ejector pins as small as 0.254mm (0.010 in.);
- a full understanding of gate and ejection location; and
- a full understanding of the effect material selection can have on fill and definition of features.
How do you ensure repeatability in production?
Repeatability stands as a fundamental pillar in the realm of micromoulding. It’s not just about crafting intricate components but ensuring that every single piece, even in high-volume production runs, meets the same exacting standards of quality and precision. Such consistency safeguards the reliability of the products, emphasising the importance of meticulous process control in micromoulding projects.
What quality control measures do you have in place?
In the precise domain of micromoulding, rigorous quality checks cannot be overemphasised. Given the minute scale and the demand for exactness, any minor oversight can lead to significant product discrepancies. Therefore, it’s imperative for companies to have a robust quality assurance system in place, ensuring that every micromoulded component aligns perfectly with the set specifications and standards, guaranteeing reliability and excellence in every production run.
Micromould quality assurance begins at the start of each project with design for manufacturability (DfM) reviews to ensure the project gets off on the right foot. Then, early in the production process, it is important to scrutinise production quality and the robust nature of the process and verify the plan for inspecting and measuring outcomes. From there, it’s important to develop control plans that address critical features, failure modes and effects analysis (FMEA) results and other quality requirements.
Most experienced micromoulders are able to use high-tech and low-tech measurements, and precision gauge pins or high-resolution in-line vision systems as necessary. It is also important to use high-magnification microscopic measurements to verify tool and finished part dimensions. Proper product handling is also a necessary consideration in quality assurance. Surface contamination can be a nuisance, or a catastrophe, for delicate component features. For these types of parts, automation and cleanroom moulding options are recommended.
How do you handle mould design and validation?
The efficacy of the mould design and its validation process is pivotal in determining the quality of the final micromoulded product. An optimised and streamlined design process not only guarantees superior outcomes but also offers the dual benefits of cost efficiency and swifter turnaround times. Companies that invest in refining these processes are better positioned to deliver high-quality products while achieving operational savings and timely deliveries.
What is your production capacity and lead time?
Ensuring a company’s capability to meet specific volume demands and adhere to set timelines is paramount in a production partnership. This not only reflects its operational efficiency but also its commitment to client satisfaction. By verifying these capabilities upfront, one can establish a foundation for a reliable and seamless collaboration, minimising potential disruptions and guaranteeing timely product deliveries. Most customers look for scale—can my micromoulder meet my production demands and hold the required tolerances?; capability—does my micromoulder have the assets in place to be successful in micro in size, micro in tolerance and/or micro featured parts; and sustainability—will my micromoulder be viable long term with a strong balance sheet?
How do you manage tool maintenance and longevity?
Consistent maintenance of moulds is a critical step in ensuring their prolonged usability and efficiency. By upkeeping the moulds, companies can assure that the quality of the products remains consistent over time. Additionally, this diligent approach helps in pre-empting and minimising sudden production disruptions. In essence, regular mould maintenance serves as a safeguard against compromised product quality and unplanned production halts, ensuring a smooth and dependable manufacturing process.
Do you offer any post-moulding services like assembly or packaging?
In the intricate world of micromoulding, ensuring a company’s capabilities and expertise is paramount for clients who require high-volume and repeatable production. While the micromoulding process itself is essential, what happens after can significantly influence the quality and reliability of the final product. For prospective customers of micromoulding companies, it’s vital to enquire about post-moulding services. Depending on the precise needs of a project, these subsequent services can be the defining factor in achieving the desired specifications and finish for micromoulded parts. As such, customers should prioritise asking detailed questions about a company’s post-moulding procedures and capabilities to guarantee that the end product not only meets the set standards but is also delivered consistently across large batches.
How do you address unforeseen challenges during production?
The realm of micromoulding, given its intricate nature, often presents unpredictable challenges. The minute dimensions and precision required can lead to unexpected complexities during the production process. In such a nuanced field, the true measure of a micromoulding company isn’t just in its ability to produce but also in its capacity to swiftly adapt and address these unforeseen challenges. As customers navigate the market, they should recognise that a micromoulder’s adaptability and proactive problem-solving approach can significantly set it apart from competitors.
Do you have any certifications relevant to my industry?
In industries where precision and compliance are paramount, such as healthcare, the importance of certifications cannot be overstated. These certifications serve as more than just badges of honour; they are tangible evidence that a company consistently meets and upholds industry-specific standards and practices. By obtaining and maintaining these credentials, a company signals its dedication to excellence and its commitment to delivering products or services that are safe, reliable and of the highest quality. For stakeholders, certifications act as a reassuring benchmark, indicating that they are partnering with an entity that understands and respects the nuances and demands of their industry.
When seeking a reputable micromoulder, you should look for the ISO 13485 Medical devices quality management systems, ISO 9001 Quality management systems and ISO 14001 Environmental management systems certificates.
What technologies and machinery do you employ in the micromoulding process?
In micromoulding, the role of modern technology cannot be emphasised enough. Employing up-to-date technology not only elevates the overall quality of the moulded products but also boosts efficiency, ensuring that projects are completed in a timely manner. Furthermore, the latest technological advancements play a pivotal role in guaranteeing repeatability, which is a critical factor when producing high-volume batches that must have consistent specifications. The adoption and application of modern technology or the bespoke in-house development of cutting-edge technology by a micromoulding company stands as a key indicator of its ability to deliver superior and consistent results.
How do you handle design changes or iterations during the project?
In the dynamic landscape of product development and manufacturing, design iterations are often an inevitable part of the journey. As such, a micromoulding company’s ability to be flexible and swiftly accommodate these design changes becomes paramount. Such flexibility not only demonstrates a commitment to customer satisfaction but also leads to significant savings in both time and resources. By pre-emptively addressing and integrating modifications, potential roadblocks are avoided, ensuring a smoother and more efficient production process. Therefore, when selecting a micromoulding partner, it’s wise to prioritise those companies that showcase this adaptability.
How do you stay updated with industry trends and technological advancements?
In today’s rapidly evolving business environment, a micromoulding company’s commitment to continuous learning and adaptation becomes a hallmark of its long-term viability. Such companies don’t just rest on their laurels; instead, they are in a relentless pursuit of knowledge, ensuring they remain at the forefront of industry trends and innovations. By fostering a culture of ongoing education and adaptability, they position themselves to offer solutions that are not only effective but also attuned to modern requirements and challenges. For clients and partners, collaborating with such forward-thinking entities often translates to innovative approaches, better outcomes and a shared journey of growth and evolution.
Summary
Finding the right micromoulding company requires due diligence and a deep dive into its capabilities and methodologies. The answers to these questions will not only give you confidence in your partner but also ensure that your micromoulded parts are of high quality, delivered on time and produced repeatably. Remember, it’s not just about finding a vendor but forging a partnership for mutual success.
Accumold