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Vacuum Casting Designing Medical Instrument Handles Surgical Equipment Polycarbonate Polyethylene
Product Description:
The medical industry relies on precision and durability in the design of surgical instruments and medical equipment. Vacuum casting plays a vital role in creating high-quality prototypes and production parts for medical devices, particularly for components like instrument handles and surgical tools. Materials such as Polycarbonate (PC) and Polyethylene (PE) are commonly used in medical device manufacturing due to their superior mechanical properties, biocompatibility, and resistance to sterilization processes.
Polycarbonate is known for its excellent impact resistance, transparency, and strength, making it an ideal material for surgical instrument handles and housings. It can be molded into complex shapes, providing ergonomic designs that are comfortable for healthcare professionals to use during surgeries. Polyethylene, with its lightweight nature, chemical resistance, and biocompatibility, is often used in the production of medical device components that come into direct contact with the human body, such as syringes, connectors, and other disposable instruments.
The vacuum casting process allows manufacturers to create medical device components with precise dimensions and excellent surface finishes. It begins by creating a master model, often a 3D-printed prototype or a pre-existing device, which is then used to make a silicone mold. Liquid Polycarbonate or Polyethylene is injected into the mold under vacuum pressure, ensuring that the resin fills.
Applications of vacuum casting
Vacuum casting is one of the most cost-effective ways to produce high quality, low volume plastic parts which can be similar to injection moulding parts
The parts are especially suitable for form, fit and function tests during the embodiment design stages, where they can be used for marketing, field user testing and product design verification purposes
There are many Urethane casting resins commercially available that can be used to create parts to satisfy a wide range of design requirements such as temperature requirements, different surface textures, hardness, etc.
Materials are also available to create parts that are fully opaque, translucent or completely transparent
Sometimes high-quality wax masters can be made using vacuum casting for investment casting to increase the finer details of intricate features
| Time frame | Within 24 hr – 5 working days for up to 30-50 parts |
| Material choice | Wide variety of materials available |
| Accuracy | ±0.3% (with a lower limit of ± 0.3 mm on dimensions smaller than 100 mm) |
| Minimum wall thickness | To ensure that the mould is filled properly, a wall thickness of at least 0.75 mm is necessary. But best results are achieved with a recommended wall thickness of 1.5 mm |
| Maximum part dimensions | The size of the mould is limited by the dimensions of the vacuum chamber |
| Typical quantities | Up to 50 parts per mould |
| Surface structure | Gloss to Matt surface finish can be obtained |
Polyurethane (PU), the full name of polyurethane, is a polymer material formed by polyol and polyisocyanate through polycondensation reaction with excellent mechanical properties
[1], which is extremely plastic. Its synthesis can be traced back to 1937, when Professor Byaer first synthesised straight-chain linear polyurethane resins using 1,6-hexanediisocyanate and 1,4-butanediol as raw materials
[2]. Several major classifications of polyurethanes include polyether-type, polyester-type, polyimide-type, and polyurea-type, etc. They can be made into materials such as polyurethane plastics (mainly foams), polyurethane fibres (known as spandex in China), polyurethane rubbers and elastomers
[3].After nearly eighty years of technological development, this material has a wide range of applications involving products such as coatings, adhesives, fabric finishes, leather modifiers, polyurethane soft/rigid foam, elastomers, etc., which are used in the fields of textiles, construction, aviation, shipping, transportation, medicine, electronics, and so on.
Flexible polyurethane mainly has a linear structure with thermoplasticity, which has better stability, chemical resistance, resilience and mechanical properties than PVC foams, with less compression variability. Heat insulation, sound insulation, shock resistance, anti-virus performance is good. Therefore, it is used as packaging, sound insulation and filtration materials. Rigid polyurethane plastic is lightweight, sound insulation, superior thermal insulation performance, chemical resistance, good electrical properties, easy processing, low water absorption. It is mainly used in construction, automotive, aviation industry, thermal insulation structure materials. Polyurethane elastomer performance between plastic and rubber, oil resistance, abrasion resistance, low temperature resistance, aging resistance, high hardness, elasticity. It is mainly used in the shoe industry and the medical industry. Polyurethane can also make adhesives, coatings, synthetic leather, etc.
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