- Process/Case Studies
- Foam Intelligence
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Next, we built the multi-cavity production tooling and tested it to ensure we could replicate the prototype parts. The transition from prototype tooling to production tooling isn’t always as simple and straightforward as it seems.
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Again, due to depth of draw of the parts, the material was tearing in the molding process. We had to experiment with different process variables in order to mold multiple parts at once and not have any defects. Ultimately, we were successful and we molded and inspected first article parts. The customer also approved the production tooling, process and parts.
After receiving first article approval, we began producing parts on a monthly basis. This project has been ongoing for about 10 years, and there have been no quality issues in that time.
The success of this joint product development effort between Flextech and our customer in the medical device market illustrates the benefits of close collaboration in developing a new product to meet customer needs.
By connecting and collaborating with Flextech, we were able to help them solve an expensive packaging problem. Our thorough understanding of the functional requirements, as well as the ability to experiment with process variables, allowed us to overcome design and manufacturing challenges that may have derailed other suppliers.
Following design approval, we were able to experiment and ultimately develop a cost-effective manufacturing process that allowed us to provide the functional parts they required.
Finally, once our customer tested and approved our prototype parts, we were able to scale up our manufacturing process to produce and deliver high quality molded foam trays. These cross-linked polyethylene foam trays provide consistent impact protection and resilience to protect fragile – and expensive – blood pumps.