Apresentação do PowerPoint - omtecexpo.com€¢ excellent tactile properties • narrow...
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Transcript of Apresentação do PowerPoint - omtecexpo.com€¢ excellent tactile properties • narrow...
Injection Molding
David Cislaghi
Product Development ManagerEnsinger Brazil
2014
Bild
ENSINGER
Converting machined metal and plastic devices for injection molding process
David Cislaghi
OMTEC 2014, July 11
• Ensinger Group / Brazil
• Design consideration – Metal / Plastic – Machining / IM
• Prototype options
• Tool strategies for low volume
• Material selection
• Applications
Topics
Today, ENSINGER Group, one of the world
leaders in engineering and high
performance plastics, with headquarter in
Germany and 30 facility's with units in
Europe, North and South America and Asia.
ENSINGER Group was founded by Mr.
Wilfried Ensinger in 1966, a small
company in his garage in Ehningen
Germany (Near Stuttgart) with the idea
of provide plastics solution .
Ensinger Group
ENSINGER Worldwide
Ensinger in numbers:
Headquarter in Nufringen
( Germany )
2.100 workers
30 facilitis
Annual sales tornover 350 MI EUR
Family company
Directors Mr. Klaus Ensinger and
Dr. Roland Reber
Automotive Medical Aerospace
Oil and gas Construction Food and beverage
Presence in the major market and industries
ENSINGER business
Extrude and cast profiles Machined parts
Sintered parts
Injection molding parts
Compounding Special profiles
ENSINGER materials
Plastics piramid
Ensinger Brazil
Founded in 1996 and producing
since 2000 in Brazil, Ensinger is
located in São Leopoldo city, Rio
Grande do Sul state.
Ensinger Brazil produce and distribute engineering and high performance
materials to a variety of applications, sending products to all regions of Brazil
South America, North America and Europe.
Ensinger Brazil in numbers
• 90 Workers
• Annual Sales of 16,5 MI USD
• Run injection molding, extrusion, cast e and machining parts
• Capacity of over 200 tons / month
• Facility of 4.900 m 2
Ensinger Brasil Certifications
Ensinger Brazil is certify under ISO 9001 on its
process since 2002, with the scope of developing,
production and sale of profiles and custom parts of
injection molding and machining of engineering and
high performance plastics.
Design considerations for IM parts
• Use of plastics
• Chemical resistant
• Low friction coef.
• Good wear properties
• Self lubricant
• Electrical isolation
• Transparency
• Low weight materials
Metal and Plastics
• Use of metal:
• High mechanical resistance
• High hardness
• Tight tolerances ( µm )
• Unit high loads / pressure
• High temperatures *
• Allow heat conductivity *
• Low CLTE *
Design considerations for IM parts
Metal and Plastics – some comparison
• Plastics:
• Low density
• High design flexibility
• Most cases no secondary operations
• High chemical resistance – corrosion
• Produce directly in color – no need for painting
Design considerations for IM parts
Metal and Plastics – some comparison
• Plastics:
• Low density
Design considerations for IM parts
Metal and Plastics – some comparison
• Plastics:
• High design flexibility
Design considerations for IM parts
Metal and Plastics – some comparison
• Plastics:
• Most cases no secondary operations
Design considerations for IM parts
Machined parts / IM parts - Consideration
• Material Selection - different processing
• Part design
• Thickness – as thick needed and thin as possible
• Flat areas x surfaces – resistance
• Draft angles / radii & corners / ribs
Design considerations for IM parts
Machined parts / IM parts - Consideration
• Material Selection - different processing
Design considerations for IM parts
Machined parts / IM parts - Consideration
• Part design
Design considerations for IM parts
Machined parts / IM parts - Consideration
• Thickness – as thick needed and thin as possible
Design considerations for IM parts
Machined parts / IM parts - Consideration
• Flat areas x surfaces – resistance
Design considerations for IM parts
Machined parts / IM parts - Consideration
• Draft angles / radii & corners / ribs
Prototipes options and considerations
• From Machining stock shapes:
• Low quantities
• Most of the cases good representation of the final part
• Good functionality – tests and prototypes validation
• Most of the materials available
• From prototype IM tool:
• Low and medium quantities - tool options*
• IM process testing and evaluated
• Representation of the final production part
• Good functionality – tests and prototypes validation
Low volumes strategies – low cost tools
• Multi part mold base
• Mechanical extraction systems
Low volumes strategies – low cost tools
• Tools with more than one different piece
• In house tool design
Material selection - Biocompatibility
Material ISO 10993 USP Vl
TECASON P
XRO*
Maximization Sensitization, Intracutaneous Reactivity, Acute Systemic Toxicity, Hemolysis and
individual cytotoxicity test by color yes
TECANYL MT
XRO*
Maximization Sensitization, Intracutaneous Reactivity, Acute Systemic Toxicity, Hemolysis and
individual cytotoxicity test by color
TECAPEEK MT Intracutaneous Reactivity, Hemolysis, cytotoxicity test by color offering
Full range of required testing supported by TECAPEEK CF30 testing
TECAPEEK
Classix*
Maximization Sensitization, Intracutaneous Reactivity, Acute Systemic Toxicity and Cytotoxicity
by resin lot with additional cytotoxicity on extrusion lot yes
TECAPEEK
XP98 & CF30*
Maximization Sensitization, Intracutaneous Reactivity, Acute Systemic Toxicity, Hemolysis and
individual cytotoxicity test by color
TECAPEI Ultem 1000
yes
TECANAT Lexan 104
yes
TECAFORM MT Ticona M25
On resin by Ticona: Intracutaneous reactivity, Acute Systemic Toxicity, Hemolysis and
cytotoxicity test. Ensinger has some cytotoxicity tests by color yes
TECAPRO MT Cytotoxicity test yes
Material selection - sterilization performance
Material Radiation Autoclave ETO
PEEK Excellent Excellent Excellent
Tecason P
(Radel R or Ultrason
P)
Excellent Excellent Excellent
Tecapro MT Poor Excellent Excellent
Tecanyl MT Excellent Excellent Excellent
Ultem 1000 Excellent Good Excellent
Polysulfone Excellent Fair Excellent
Hydex 4101 Good Poor Excellent
Acetal Poor Fair Excellent
Acrylic Poor Poor Good*
• Light probe for caries diagnosis, made from TECAPEEK MT sw
• excellent tactile properties
• narrow manufacturing tolerances
• can be autoclaved
• Catheter pump from TECAFINE PP
• flexible, biocompatible
• non-polar surface and high resilience (non-
breakable)
Applications
• Part for dentists‘ tools made from
TECAPEEK sw and red
• resistant to hydrolysis
• resistant to chemicals
• high form stability (min 5,000 locking
repetitions)
• FDA and USP conformity
• Endoscopy tongs: Grips made of
TECAPEEK MT; for use in medical
technology
• resistant to hydrolysis
• low weight
• ergonomically advantageous shape
Applications
• PercuTwist-Dialator: Medical instrument (for
tracheotomy)
• injection moulded blank, machined finished part
• TECAPEEK MT blue
• sterilisable, high strength and toughness
• easy handling due to low weight
• Light Cycler for use in DNA analysis
• injection moulded blank, machined finished part
• Capillary sample holder made of TECAPEEK MT,
which is able to withstand extreme temperature
changes caused by fast cycle times in use
• laser marked
Applications
Muito Obrigado!
Thank you !
Contact information:
David Cislaghi
Phone: 55 51 3579 8833 / 55 51 84336883
