Protolabs

London based firm Entryphone has been designing, manufacturing and installing door entry systems since 1958. Now, over 60 years on, son Oliver Ashbee heads this family business. Oliver is passionate about using his decades of experience to develop innovative products that meet the demands of the 21st Century.Oliver’s latest concept is an entry phone for the smart phone generation. His aim is to create a product that is simple in functionality with an aesthetic that will appeal to architects and developers who are looking for something sleek and stylish for their high-end city-centre dwellings.Entryphone manufacture many of their own products, utilising a large warehouse at their premises in Wandsworth. However, the company called on <a href="https://www.protolabs.co.uk/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-case-study-0121&utm_content=entryphone-0121" rel="noopener noreferrer" target="_blank">Protolabs</a>’ expertise for support in producing the casing for the new entry phone. As Oliver explains:“The 516v has been a couple of years in the making. After initially getting in touch with Protolabs to produce the 3D printed prototype using their stereolithography (SLA) technology, I was keen to utilise Protolabs again to quickly ramp up production with tooling and moulding for the casing.<blockquote><blockquote>“Protolabs’ quoting system, where you can upload CAD models onto their website, really is brilliant. The interface is really easy to use and then it takes a good look at your design and gives you feedback for production. It’s an invaluable tool.” - Oliver Ashbee, Director, Entryphone</blockquote></blockquote>Oliver uploaded his CAD file to Protolabs’ online quoting platform and, whilst the part was manufacturable, the design for manufacture (DFM) analysis software identified a couple of areas where manufacturability improvements could be made.&nbsp;In response, Protolabs Application Engineer, Charlotte-Anne Smith arranged a call with Oliver and they discussed the advisories that had been flagged up. These included a thickness on one part of the geometry that may have resulted in sink marks as well as thin and zero draft areas. Once identified, Oliver was able to quickly address and eliminate these areas on the final CAD design and thus enhance the part’s mouldability.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610525794540-1610525794540.png" style="width: 300px;" class="fr-fic fr-dib">After going through the technical elements, Charlotte-Anne advised Oliver on <a href="https://www.protolabs.co.uk/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-case-study-0121&utm_content=entryphone-0121" rel="noopener noreferrer" target="_blank">injection moulding</a> tolerances that Protolabs work to. Oliver was clear from the start that he wanted an ABS white as his material, which just left the surface finish to choose. To assist with this, Charlotte-Anne arranged for a sample plaque of the different finishes that can be achieved on Protolabs’ stocked materials. Oliver subsequently chose SPI-A2, the highest polish finish.Protolabs’ quote included a gate and ejector layout. Charlotte-Anne and Oliver had a few discussions about the gate layout because of the high polish finish on the outside of the part. The original gate layout was located on the area of high polish finish, which would leave a gate scar Charlotte-Anne was able to compose a gating option in a different location that would not affect the cosmetic appearance of the part.“It was good working with Oliver as although his design was manufacturable from the outset, he had the flexibility to tweak and refine his design for the injection moulding process. It’s satisfying to have those conversations upfront with a client about the draft, the gate and the ejector layout, and see how the suggested changes are implemented into a design that makes for an even better part – one that the client is really happy with. It gives me great job satisfaction,” explained Application Engineer Charlotte-Anne Smith.A third and final iteration was uploaded and a simple, single cavity, standard open shut mould – with just a core and the cavity – was swiftly made. From this tool, Protolabs was able to rapidly produce a sample production batch of 50 cases. All this within just 15 days.<blockquote><blockquote>“The turnaround that Protolabs offers – on the quotation, the tooling and the moulding – is really appealing. Protolabs are great because not only can you get a sample or production run turned around quickly, you get their expertise and support as well. The DFM report comes back swiftly and the Application Engineers are excellent. Protolabs do this so much better than anyone else out there.”</blockquote></blockquote>“The speed of the tooling was pretty key to all this because when you’re ready to go, you’re ready to go,” explained Oliver. “We had challenges our end with the circuit boards and getting the audio right on this product, so once we nailed that, we just wanted to get going. We didn’t want to be sat around for weeks twiddling our thumbs, so getting samples back in 15 days is a wonderful thing. We are raring to go and keen to get this product out into the market place.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610525831146-1610525831146.png" style="width: 300px;" class="fr-fic fr-dib">The finished 516v entry phone measures approximately 20cm tall and 8cm wide and will be wall mounted. The white ABS case produced by Protolabs supports a glass screen. When answering the door, a colour image of the person at the door can be seen and the user has 6 touchscreen icons to choose from, including unlock door, mute, switch views between cameras and to ring the porter for those living in apartments with a concierge service.&nbsp;<blockquote><blockquote>“I’m really pleased with the product and Protolabs have been great as far as I’m concerned. Their service has made my life easy, and that’s very important. I will certainly be using them again. Very few people do what they do as well as they do. They occupy that space in the market very well. When it comes to tool making, there are very few people that are very good at it, but they make it easy.”</blockquote></blockquote>Oliver will be soft launching the new 516v entry phone soon, with a full production run from Protolabs in the new year. And always looking to innovate, he’s already working on a new product that will be revealed next year. &nbsp;&nbsp;About EntryphoneEntryphone is a family business formed in the late 1950s as a designer, manufacturer and installer of door entry systems. The last 60 years has seen a great deal of innovation in this area and Entryphone has been at the forefront of this advancement.

Entryphone have developed an entry phone product that perfectly meets the demands of the 21st century. Keen to get their exciting new product to market as quickly as possible, Protolabs' high-speed low-volume production model provided the support needed.

Protolabs supports the development of an entry phone for the smart phone generation

<a href="https://kyronmax.mcam.com/" target="_blank">KyronMAX®</a> is a range of high strength thermoplastic composite compounds from Mitsubishi Chemical Advanced Materials, specifically designed for rapid, complex high-spec injection molding. KyronMAX® is also an engineering platform where engineers collaborate with experts who understand the material, allowing prototyping to be completed within days. The KyronMAX® technology is designed to be applicable in low, medium, or high-volume parts production.&nbsp;<h1>Stronger than steel, lighter than aluminum, and sustainably recyclable</h1>KyronMAX® is among the most robust injection moldable products available in the world today. The series of products significantly changes the way design engineers can think of plastic materials. The unique combination of KyronMAX®’s high-pressure molding technology with advanced material technology produces high-strength structural thermoplastics that offer mechanical properties that meet, and in some comparisons, exceed those of metals.KyronMAX® features:<ul><li>Light, reduced material volume required (75% lighter than steel and almost 40% lighter than aluminum).</li><li>Easily processable (can be molded using the same equipment and tooling as standard or unfilled resins).</li><li>Compounds can be customized to meet application requirements, in addition to standard, readily available product offerings.</li><li>Retains high strength in complex part geometries (with multiple knit lines), where traditional Long Fiber Thermoplastics struggle.</li><li>55k+ PSI tensile strength.</li><li>&lt;30% lower component cost per unit.</li><li>Metal to plastic conversions, without the cost and lead time of traditional metal tooling or penalties for multiple design changes.</li><li>Prototype parts using the same resins as production injection molded parts.</li><li>Surface finishes and features that cannot be replicated by machining or 3D printing.</li></ul>The KyronMAX® series of structural thermoplastic materials outperform the mechanical strength of long fiber thermoplastic (LFT) materials, especially when measuring a molded part’s performance. The material overcomes the limitations of LFT compounds while yielding stronger molded parts that are also lighter in weight.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMTA0NDExNjMzLWltYWdlMTIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 800px;" class="fr-fic fr-dib">KyronMAX® is suitable for, but not limited to applications including<ul><li>Automotive</li><li>Prosthetics</li><li>Drone and UAV casings</li><li>Sports and leisure equipment</li><li>Industry</li><li>Robotics</li><li>Consumer product design</li><li>Wearables</li><li>Aerospace</li></ul>What makes the KyronMAX® material technology unique is its short fiber technology, which means the polymer behaves more like the isotropic nature of metal and eliminates the processing and fiber breakage concerns associated with LFT compounds. The technology enables very complex parts to be molded with high mechanical performance and consistency.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMDk2NDk5NDA4LUt5cm9uTUFYIHNob3J0IGZpYmVyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 800px;">Image 1: KyronMAX® short fiber technology versus LFTCompetitive structural compounds use high fiber loadings and long fiber lengths to achieve the desired mechanical performance. Unfortunately, these materials’ performance does not translate into the molded parts, due to weld line strength loss and fiber length reduction during processing. In contrast, the KyronMAX® material technology outperforms other thermoplastic compounds using short fiber technology and much lower filler loadings. The lower filler content results in a tough, structural plastic that can be utilized in extremely aggressive applications yet is still processing friendly and does not require specialized molding equipment.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMDk5MDI3NjMzLUt5cm9uTUFYIHRlbnNpbGUgc3RyZW5ndGggVE0uanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 800px;" class="fr-fic fr-dib">The KyronMAX® platform features a range of high-strength carbon fiber-based composites that allows you to buy-off-the-shelf, top-performing materials or customize your own formulation to match your requirements. Each formulation has specific properties that make it suitable for different applications. See here how the <a href="https://kyronmax.mcam.com/about-kyronmax" target="_blank">KyronMAX® range compares</a> to each other and other common injection molding materials.<h1>The KyronMAXⓇ&nbsp;platform</h1>KyronMAX® is more than a material; it is also an engineering partnership. From design to functional prototype, to production and all the way through to zero waste, engineers work together with Mitsubishi Chemical Advanced Materials to solve materials engineering challenges. The KyronMAX® collaboration happens in three phases.Phase 1 - Diagnostics: content deep dive, feasibility check, AI-based business intelligence.In this phase the overall feasibility of the project is assessed from both a materiality and business perspective.Phase 2 - Design Sprint: MVP designMVP (minimum viable product) design is a process for creating functional, production-ready products that serve to test ideas and complete a design process. Puts functional parts with true properties into customer’s hands quickly to accelerate the design cycle and lock-in material specifications.Phase 3 - Delivery Sprint: functional prototype creation and testing, plus approach to recyclingSPRINT (Soluble PRinted INjection Tooling) technology means functional prototypes can be developed in just a few days. SPRINT allows for rapid injection molding of functional parts in the right material. Alongside digital twinning, it means real world designs can be tested quickly and accurately, shortening design timelines and meeting production deadlines faster.&nbsp;SPRINT combines the speed and agility of 3D printing with the accuracy of injection molding. Unlike other injection molding processes, the KyronMAX® SPRINT can produce material accurate prototypes in just days rather than weeks. A 3D Resin mold is first 3D printed, this is then injected with the chosen polymer. The resin is then ‘washed’ away to reveal the prototype part.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMzU5NzYwNTk2LTEuMS0wMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 800px;" class="fr-fic fr-dib">Throughout the three-stage journey, KyronMAX® experts support engineering teams on:<ul><li>Material selection</li><li>Part design</li><li>Test and production of functional prototype with SPRINT (Soluble PRinted INjection Tooling) technology</li><li>Setup of production scale up plan</li><li>Assessment of the project’s recycling possibilities in order to create zero waste</li></ul>Designers and engineers working with KyronMAX® are supported throughout the whole process from ideation to final product no matter if the project is a small-batch prototype or fully commercial product. Read more about the collaborative KyronMAX® platform h<a href="https://kyronmax.mcam.com/working-with-us" target="_blank">ere</a>.<h1>A new standard in sustainability</h1>KyronMAX® injection moldable composites can be returned to create zero waste using their end-of-life recycling program, while their vertically integrated and closed-loop supply chain is key to all KyronMAX® engineering partnerships. Their commitment to sustainability goes beyond simple recycling their materials and minimizing their impact. KyronMAX® uses digital twins to test new ideas, their focus on small batch prototyping means their entire production process is further designs to minimize waste and maximize speed to market.The key advantages to this focus on sustainability includes:<ul><li>Faster production lowers overall energy costs while lightweight formulations reduce the overall manufacturing footprint as well as and improves fuel economy, energy use and longevity in applications from aviation to robotics.</li><li>The KyronMAX® tailor-made injection moldable carbon-fiber composite compounds can be reused and returned to create zero waste using our end of life recycling program.&nbsp;</li></ul>The production process allows for any scrap, waste, or unused products to be taken back and recycled without down cycling.<h2>Light weighting and metal replacement</h2>Plastic replacement of metal generally offers advantages to designs, including the potential to be lighter, cheaper, or more quickly produced. However, most high-strength moldable plastics are nowhere near the strength of metals so the metal part geometry must be altered and re-engineered to utilize plastic materials. This often involves adding more material volume of the plastic which can increase the weight and cost of the part. Thanks to KyronMAX®’s high strength properties and complex geometries, component design can more easily replicate the original metal design, reducing material volume while realizing all the benefits of the plastic material.A great example is the KyronMAX® #10-32 bolt that responds to multiple requests from OEMs for an injection moldable thermoplastic composite bolt that exhibits metal-like strength. These end-users were looking for a plastic fastener to replace traditional titanium metal fasteners for weight savings but could not find a polymer with enough mechanical performance, or that was economically viable. The KyronMAX® #10-32 bolt meets both the strength and the cost target requirements for the application while reducing the weight of incumbent titanium bolts by approximately 60%! Read more about KyronMAX®'s commitment to full life-cycle sustainability <a href="https://kyronmax.mcam.com/" rel="noopener noreferrer" target="_blank">here.&nbsp;</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMzc0NDEzMDE4LUt5cm9uTUFYIGJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 788px;" class="fr-fic fr-dib"><h1>The KyronMAXⓇ&nbsp;Challenge</h1><a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">The KyronMAX®&nbsp;Challenge</a> invites you to submit a design that utilizes KyronMAX®’s range of breakthrough, high strength carbon fiber-based composites to solve an engineering or manufacturing challenge. The winning designs will receive $25,000 worth of manufacturing support from KyronMAX® to create a fully developed prototype.Your submission can be a stand-alone product or a component of a larger design. Successful submissions will need to show how the design utilizes the unique properties of KyronMAX® materials and complements the platform’s capabilities. The KyronMAX® challenge will reward projects that prioritize sustainability while maintaining a high level of feasibility and ingenuity.For full challenge details see <a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">The KyronMAX®&nbsp;Challenge homepage.&nbsp;</a><hr><h1>About the sponsor:</h1>Mitsubishi Chemical Advanced Materials is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a broad variety of customer markets. The Mitsubishi Chemical Advanced Materials Group is well prepared to further expand its market leadership position.Supporting the vision of our holding company, <a data-saferedirecturl="https://www.google.com/url?q=http://www.mitsubishichem-hd.co.jp/english/index.html&source=gmail&ust=1610465953419000&usg=AFQjCNFACQRncQmFf1bOAoQ_uuE9Ax8efA" href="http://www.mitsubishichem-hd.co.jp/english/index.html" target="_blank" title="http://www.mitsubishichem-hd.co.jp/english/index.html">Mitsubishi Chemical Holdings Corporation (MCHC)</a>, Mitsubishi Chemical Advanced Materials is committed to the realization of KAITEKI, “a sustainable condition which is comfortable for people, society and the Earth”. To realize this vision, the MCHC Group engages in corporate activities that provide products, technologies and services based on the comprehensive capabilities of the Group in the Performance Products Domain, Industrial Materials Domain and Health Care Domain, with chemistry as the basis of our activities. We jointly express and promote our commitment under the corporate brand THE KAITEKI COMPANY.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMzc5ODcyNzM3LWxvZ28gZm9vdGVyIE1DQU0uanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 788px;" class="fr-fic fr-dib">

KyronMAX®’s carbon fiber-based technology platform provides material-accurate prototyping in just days.

New manufacturing platform combines agility of 3D printing with strength of injection molding for rapid prototyping

Even a perfectly designed injection-moulded part can fail if manufactured from the wrong material, and with literally <a data-udi="umb://document/4d9db293978f46109e63376d0b1adcad" href="https://www.protolabs.co.uk/materials/comparison-guide/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-comparison-guide-link-0121" rel="noopener noreferrer" target="_blank" title="Comparison Guide">hundreds of thermoplastics and elastomers</a> to choose from, it’s often difficult to know which ones will meet the application’s requirements. This is why a host of factors such as mechanical strength, chemical and ultraviolet light resistance, lubricity, wear resistance, and more must be carefully considered when selecting materials for injection moulding. &nbsp;This situation becomes even more challenging with overmoulded parts, where designers must not only adhere more closely to established moulding principles, but also make certain that the chemical and physical bonds between their chosen materials are both strong and permanent. This tip discusses three key areas—material compatibility, adhesion, and tribology—that designers should be knowledgeable about when designing moulded parts.<h3>Friction and Wear</h3>Let’s start with a term not often heard on the manufacturing floor. Tribology is the study of friction and wear that occurs between two surfaces moving relative to one another. It concerns the interaction between the interlocking clips and tabs of a snap-fit container, for example. An engineer looking at the tribology of parts would probably care less about the chemical and mechanical bonds needed to overmould a handle for a power tool (because they don’t slide against one another, assuming the design is sound), and more about the feel and grippability of the overmoulding material itself. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA5OTIwMzYyNzQwLW1vbGRlZC1wbGFzdGljLWdlYXJzLWlsbHVzdHJhdGlvbi1vZi1mcmljdGlvbi1hbmQtd2Vhci01NzB4MzA4LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=">These plastic gears moving together show how a part design can be influenced by the friction and wear that occurs between surfaces interacting with one another, an important element to consider when selecting materials for your moulded parts.&nbsp;In the snap fit clip example, a wear-resistant polymer such as HDPE might be a good choice, although a relatively lubricious material like acetal could also be a candidate. Both materials have their own unique virtues that should be carefully weighed early in the development process. Yet the product design itself can also play a huge tribological factor. Surfaces that interact with one another should be smooth, lest the miniature peaks and valleys found on rougher surfaces catch and break away with repeated use.The method used to manufacture the part also plays a role. In the clip example, which can easily extend to any number of plastic parts with mating or interlocking surfaces, a machined finish is different than a 3D-printed one, as is an injection-moulded surface (and is likely to be smoother than either). The message here is that these and other part characteristics should be carefully analysed and tested before traveling too far down the design road when part interaction is a design concern.Here’s another example. Metal inserts are a popular option at Protolabs. Whether you need a bronze bushing in an injection-moulded fan blade, a stainless steel sleeve in a plastic pulley, or a threaded brass nut in an equipment knob, placing these and other inserts in injection-moulded parts is no big deal. There’s little concern over material compatibility, and the biggest obstacle the designer will face is making sure that a good mechanical bond is created when the plastic is injected over and around the insert. That said, bronze and brass make for good, low-cost bearing surfaces, but are more prone to wear than an actual ball-bearing. Ask yourself this: Does your design meet the product’s long-term requirements? A good understanding of tribology will help resolve this and other important questions.<h3>Material Compatibility</h3>Few would argue that overmoulding is one of the coolest things to happen to plastic parts since quick-turn injection moulds. It’s a great option anywhere a soft or user-friendly material is needed atop a structural core—an instrument handle, perhaps, or handheld electronics housing—or where multiple colours are desired for aesthetic reasons. There’s plenty of information online about <a data-udi="umb://document/e81ee81b340348ceafdcaf74cdeec327" href="https://www.protolabs.co.uk/resources/design-tips/designing-for-overmoulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-overmoulding-dt-link-0121" rel="noopener noreferrer" target="_blank" title="Designing for Overmoulding">designing for the overmolding process</a>, discussing the need for a sound mechanical bond as well as chemical compatibility between the two adjoining materials.The good news is that a host of chemically compatible materials are available. For instance, Protolabs offers TPV Sarlink 3170 a thermoplastic elastomer that forms a strong chemical bond with polypropylene. There’s TPC Hytrel 4068 a thermoplastic elastomer that mates up just fine with ABS, polycarbonate, and more. Nylon, on the other hand, is among the more difficult substrates for overmolding due to its moisture-absorbing tendencies, though it remains a popular material across a range of applications. <img data-fr-image-pasted="true" src="https://www.protolabs.co.uk/media/1014954/chemical-adhesion-illustration-on-overmolded-parts-570x308.jpg?anchor=center&amp;mode=crop&amp;width=570&amp;height=308&amp;rnd=131780237290000000" alt="chemical adhesion illustration on overmolded parts 570x308" style="width: 300px;">Chemical adhesion of overmolded parts is tricky. The transition between substrate and overlay should be abrupt to avoid feathering/thinning. Use a groove or shoulder to create a cutoff point. Curling and tear points can be eliminated by placing the shutoff in a location that creates a hard stop for soft, flowable TPE. Figure at left shows the substrate in gray and the TPE and potential curling in blue. At right, substrate is gray and TPE is yellow, with the shutoff shown stopping the TPE. <h3>Adhesion</h3>There’s more to it than that, however. Part design can have a significant effect on the adhesion level of overmoulded parts. The transition between substrate and overlay should be abrupt to avoid feathering or thinning—consider using a groove or shoulder to create a clear cut off point. Curling and potential tear points can be eliminated by <a data-udi="umb://document/4375432824d145b0a6c2cae570e12da4" href="https://www.protolabs.co.uk/resources/design-tips/incorporating-shut-offs-in-injection-moulding-design/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-shutoffs-dt-link-0121" rel="noopener noreferrer" target="_blank" title="Incorporating Shut-offs in Injection Moulding Design">placing the shutoff</a> in a location that creates a hard stop for soft, squishy, and very flowable TPE. Use too thin of an overlay—say anything less than 1/16-inch thick—and the material may cool too quickly for proper adhesion. Long length-to-thickness ratios can cause similar problems.Also, be aware of the two materials’ unique thermal characteristics when overmoulding. You might select <a data-udi="umb://document/ac1f833b7ac644b4909bec4957ab4507" href="https://www.protolabs.co.uk/services/injection-moulding/liquid-silicone-rubber/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-service-lsr-link-0121" rel="noopener noreferrer" target="_blank" title="Liquid Silicone Rubber">liquid silicone rubber</a> (LSR) for its excellent heat and chemical resistance, low-temperature flexibility, and inherent lubricity, but keep in mind that LSR cures at 150 to 200 degrees centigrade, a temperature too high for ABS, polyethylene, polypropylene, and a number of other thermoplastics to survive. Venting is also important, as burning, insufficient adhesion, and incomplete cavity filling—short shots—can occur in an improperly vented mould.It’s easy enough to check the <a data-udi="umb://document/d4d023b2d18d4d4e821bf00d0d6f17b0" href="https://www.protolabs.co.uk/services/injection-moulding/overmoulding-and-insert-moulding/design-guidelines/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-overmoulding-insertmoulding-design-guidelines-link-0121" rel="noopener noreferrer" target="_blank" title="Design Guidelines: Overmoulding & Insert Moulding">compatibility chart</a> online, but if you prefer to supply your own material, it might be best to check with your plastics supplier for moulding and application advice. This is especially true if you’re using a custom polymer mix, which an increasing number of Protolabs’ customers do. Be aware that colourants can create adhesion problems, as can high amounts of additives such as metal and glass. Our advice is to always run a few sample parts and test thoroughly before pulling the trigger on higher volumes.&nbsp;<h3>Adhere to Design Guidelines</h3>The list of examples is long, the possible polymer combinations nearly endless. That’s why it’s important to check with someone knowledgeable on the vagaries of polymer adhesion and chemical compatibility early in the design process, to verify that A) your chosen materials will play nice together, B) the part or overmoulded assembly is moldable given your current design, and C) that the materials are tribologically sound—that is, they are slippery enough, wear-resistant enough, or sticky enough for the product’s purposes.This is one time when sticking to Protolabs’ guidelines is especially important. Using a plastic that’s high in additives might help you achieve your product requirements, but it might also mean spending more time on the product design; the “sweet spot” of mouldability becomes smaller and smaller as plastic additives increase, and only gets more challenging with high complexity parts.Scared? Don’t be. All of these situations are quite manageable, it just takes a little more attention during the design process and possibly a second look at your material selection. And when in doubt, give Protolabs a call, even if you’re just kicking the tires at this point. Between our knowledgeable staff, automated quoting process, and free <a data-udi="umb://document/430a06346a804eb892f3bb24e7b74bd0" href="https://tryit.protolabs.com/samplequote/moulding-uk/?lang=en-GB" rel="noopener noreferrer" target="_blank" title="Injection Moulding Sample Quote">mouldability analysis</a>, even the most chemically challenging materials are easy to master.As always, if you have questions or concerns, feel free to contact one of Protolabs’ applications engineers at +44 (0) 1952 683047 or <a href="mailto:customerservice@protolabs.co.uk" target="_blank">customerservice@protolabs.co.uk</a> to discuss options.

The role that material compatibility, adhesion, friction, and wear play in design of moulded parts

Why Material Science is Key to Part Interaction

Julio Aleman, a Bioengineering PhD student at the University of Pittsburgh Swanson School of Engineering is performing research in microphysiological systems.Like many researchers, Aleman needed a microwell array system with individual wells that have a specific size, shape and density. In fact, Aleman needed two different microwell arrays that would support the injection moulding of hydrogels and serve as “master moulds” – the original moulds that he could replicate. In turn, these replicate moulds would be used for microwell fabrication. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869692139-PittsburghCaseStudy2.png">Hydrogel mould of 484-microwell arrayTo produce master moulds like this, photolithography (optical lithography or UV lithography) is often used. The process begins by spin coating a negative photoresist on a wafer to establish mould thickness and microwell depth. Photopatterning is achieved by light exposure through specialised high-resolution masks and finalised by chemical development of the master mould. Then, replicas of the master mould are made by casting pre-polymers over the negative template and polymerising them by thermal curing.Polydimethylsiloxane (PDMS) silicone is the biocompatible polymer that is most often used. Typically, the production of master moulds and masks requires specialised facilities and equipment. Micro-injection moulding can also produce master moulds, but the tooling is expensive and time-consuming to produce. <h1>An Alternative to Clean Room Photolithographic and Injection Moulding</h1>Projection Micro Stereolithography (PμSL) from Boston Micro Fabrication (BMF) allows for the rapid photo-polymerisation of a layer of resin with a flash of ultraviolet (UV) light at micro-scale resolution. PμSL offers an alternative to photosoft lithography, etching, deposition, micro-injection moulding, and other traditional microfabrication methods.PμSL, a form of micro 3D printing, can produce small components with fine features and tight tolerances that are otherwise impossible to create. PμSL is capable of achieving a resolution of 2µm~50µm and a tolerance of +/- 5µm~25µm, thus providing ultra-high-resolution that is mould-free and mask-free for fast prototyping and end-use parts.  <h1>Project Requirements for Two Master Moulds</h1>The University of Pittsburgh project needed master moulds for replicate silicone moulds that, in turn, would be used to make biomaterial-based microwells. Normally, master moulds require a cleanroom and can be challenging to characterise. Researchers can’t perform profilometer measurements until the moulds are baked, and a mould with the wrong dimensions means lost time and money.Julio Aleman’s project required fast turnaround times and high-volume production. Accuracy, resolution, and precision were critically important. Several PDMS replicas that were cured at 80° Celsius were needed and the repeated processes on the master mould had to have little to no impact on the dimensions while the master mould was also securely fixed in a substrate. Aleman knew that he would need moulds in two different sizes, and that the silicone moulds should allow for the bottoms of the hydrogel micro-wells to have constant and defined amounts of biomaterial once injected and polymerized onto a glass slide. After some preliminary discussions, he ordered parts from BMF.The master moulds that the University of Pittsburgh asked BMF to produce were square with a defined hole–pattern. The first mould was for a 64-microwell array. It had an overall area of 20 mm x 20 mm and a thickness of 1.65 mm. The diameter for each hole and the distance between holes was 600 microns, or 0.6 mm, and the base of each of the microwells had a height of 50 microns from the surface. The second mould was for a 484-microwell array. The overall area was the same as for the first mould (20 mm x 20 mm), but the thickness for the second mould was significantly less at 1 mm. There were also more holes – and the holes were smaller. These wells measured just 150 microns, or 0.15 mm, in diameter with a similar base height of 50 microns.3D printed mould for 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869775020-PittsburghCaseStudy3.png">3D printed mould for 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869800497-PittsburghCaseStudy4.png">3D printed mould for 484-microwell array<h1>Expert Advice and Flexible Material Selection</h1>BMF’s application team reviewed the designs for the University of Pittsburgh moulds. They recommended increasing the thickness of the second mould to greater than 1 mm. Otherwise, a mould that is too thin may experience part distortion or internal stresses during the printing process. Aleman revised the thickness and BMF then created sample parts using GR resin, a high-performance engineering material that is black in colour, able to withstand temperatures up to 102°C, and that supports sterilising.Because the COVID-19 pandemic limited Aleman’s access to university facilities, the graduate researcher limited his mould evaluation to microscopy. In turn, this meant that parts made of a dark resin would be more difficult to inspect. To support microscopic techniques, Aleman needed a resin that would allow more light to pass through so that the features of the resin mould could be more clearly seen. The solution was to use an HLT resin instead. This yellow resin from BMF offers greater transparency but still provides good impact strength, heat resistance, and support for autoclave sterilisation.<h1> </h1><h1>Speed, Accuracy and More</h1>&nbsp;Julio Aleman was pleased with the quick lead time – the moulds were delivered in just two weeks. Instead of waiting months to get a single injection-mould, he could provide a master mould to each member of the research team. The moulds also exhibited dimensional stability and, unlike spin coating in photolithography, did not require multiple fabrication steps. After hard baking some master moulds in an oven overnight, Aleman attached them to a surface with double-sided electrical tape. The moulds experienced only a 10 to 20-micrometre reduction in size, and that may have been caused by pressing the moulds against the surface or the tape while the moulds were still malleable from baking.Aleman also reported that after approximately 10 cycles of PDMS moulding, the BMF master moulds did not exhibit any bending or deformation. To prevent sticking, the replicate moulds were salinated with Vapor Phase Deposition (VPD). This treatment, which is also used with the SU8 moulds in photolithography, permitted the easy detachment of the PDMS moulds from the BMF master moulds. Aleman reported that the master mould with the larger features was easily salinated over one hour of exposure while the mould with smaller features required five hours or overnight exposure.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869860170-PittsburghCaseStudy5.png">PDMS replica of 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869888883-PittsburghCaseStudy6.png">PDMS replica of 484-microwell array<h1> </h1><h1>Proof-of-Concept for Your Next Project&nbsp;</h1>As the University of Pittsburgh project demonstrates, researchers can use micro 3D printing to speed microwell array fabrication. If your application requires proof-of-concept parts such as master moulds, BMF can harness the power of PμSL technology on your behalf. We can also help you with material selection and recommend the best microArch printer from our growing family of ultra-high resolution 3D printers.In an exclusive partnership with BMF, CREATE Education are sharing their knowledge, support and experience, to bring micro 3D printing technology to the forefront of their education community in the UK and Ireland, enabling breakthrough research and development.CREATE Education are committed to supporting educators, educational institutions, outreach and community programs with the aim to bring cutting edge technologies throughout the world, such as 3D printers, into education.To learn more about PμSL technology and micro 3D Printing for research, please contact <a href="https://bit.ly/ContactCREATEEd" rel="noopener noreferrer" target="_blank">CREATE Education’s specialists</a>.

Julio Aleman, a Bioengineering PhD student needed two different microwell array system with individual wells that would support injection moulding of hydrogels and serve as “master moulds”

University of Pittsburgh Speeds Microwell Fabrication with Micro 3D Printing

Mould-making techniques make complicated features like o-ring grooves, mushroom studs, and text on parts possible

6 Tips for Tackling Complex Features in Moulding Design

The Evo System, from Norwegian start-up Moon Labs, is an unobtrusive, wireless and affordable solution that provides ongoing vital health information.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1600328033261-Moon+Labs_Evo+Sensor_v1.jpg" alt="Evo Sensor">The Evo Sensor sits behind the patient's earLike so many of the best ideas in life, the Evo System was conceived by a small team of people in response to a real need that was not being met. Having already prototyped it using its own 3D printing technology, the company needed to manufacture higher volumes for pilot testing and clinical trials in Norwegian hospitals.The monitoring system consists of three elements: The Evo Sensor is a small wireless disposable biosensor that sits comfortably behind the patient’s ear. It measures heart and respiration rate and oxygen saturation continuously for up to five days. The Evo Gateway transmits this data to the cloud using the communication system Fast Healthcare Interoperability Resources, or FHIR, so that it integrates directly with the patient’s electronic journal. The final part, Evo Central, is software for doctors and nurses to track multiple patients’ vital signs over time. It calculates early warning scores to highlight if their health is deteriorating and requires intervention.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1600328062055-Moon+Labs_Evo+Gateway+2_v1.jpg" alt="Box of Vodka Xau ">The Evo Gateway transmits data to the cloudHaving prototyped the design to prove the concept, the next step for Moon Labs was to move towards manufacturing the system for pilot testing and clinical trials in hospitals. For a small start-up company such costs can prove prohibitive, so Moon Labs decided to enter Protolabs’ European Cool Idea award. This award offers small companies the chance to realise their concepts by offering a grant towards building prototypes or an initial production run.In this case Moon Labs needed to move the concept from 3D printing to injection moulding so that they could produce enough numbers for pilot testing and clinical trials and also have a design for large scale manufacturing in the future.While injection moulding significantly reduces the unit cost for larger production runs, it does have certain design requirements. Product lead and co-founder of Moon Labs Tord Åsnes used Protolabs Design for Manufacturability (DFM) analysis software to develop the design and make it suitable for future mass manufacture.<blockquote><blockquote>“The European Cool Idea Award has really helped us take the Evo System onto the next stage of development and closer to a real-life solution that will save lives and cut hospital budgets. It is meant to be a cost-effective solution, so we had to find a way of mass manufacturing it to lower the unit costs."</blockquote></blockquote><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1600328079801-Moon+Labs_Evo+Central_v1.jpg" alt="Moon Labs Evo Central">Evo Central is software used to track the patients' vital signsTalking about the process, Åsnes said: “I found the DFM analysis software excellent. After uploading my design, it highlighted areas where there could be manufacturing issues and then suggested alternative solutions. I put a number of design iterations through the system and, with the help of an Application Engineer at Protolabs, came up with a design that met our needs and could be injection moulded.“The European Cool Idea Award has really helped us take the Evo System onto the next stage of development and closer to a real-life solution that will save lives and cut hospital budgets. It is meant to be a cost-effective solution, so we had to find a way of mass manufacturing it to lower the unit costs.“At the same time working within the medical devices industry, there are very strict regulations and testing that we have to adhere to. This all takes time, which means that the cost of funding this next stage of development, with a manufacturing partner who has the necessary expertise in the medical devices industry, could have proved prohibitive for us.<blockquote><blockquote>“The European Cool Idea Award from Protolabs meant that we could use their expertise to realise our solution and move it onto pilot testing and clinical trials in a hospital environment. Not only did the company help us with the design, but they also advised us on the best medical grade plastics to use.”</blockquote></blockquote>Explaining the importance of the Evo System, Nils Kristian Skjærvold, medical director at Moon Labs and senior consultant at the Department of Cardiothoracic Anesthesia and Intensive Care at St. Olav’s hospital in Norway said: “While patients in intensive care are monitored regularly, we must not forget that those people in general care in the hospital are still very ill people. There is always a chance that they can deteriorate and have a cardiac or respiratory arrest.“When we get called out in an emergency, we sometimes have no idea how long a person has been in arrest. This is a life-threatening situation that could mean that they end up in intensive care where treatment is expensive, or worse they could lose their life.“The Evo System is a cost-effective way of monitoring patients in general wards or rooms so that medical staff can see any deterioration in advance and take corrective action immediately.”After an initial production run of 500 Evo Sensors and 100 Evo Gateways, the system will be trialed in three hospitals in Norway. Moon Labs then hopes to gain CE marking and be able to manufacture the system by early 2021.Talking about the Cool Idea award, Peter Richards, Director of Marketing and Communications at Protolabs said: “There is no shortage of potentially ground breaking solutions like the Evo System that are just waiting to transform our lives.“Sadly, the problem is often the practicality of realising these concepts. While something may look good on paper or as a CAD design for many small or start-up companies there is simply not the resource and/or expertise to help them make that idea reality, which is why we have introduced our European Cool Idea award.”The award offers up to £100,000 in Protolabs manufacturing services, split over four quarterly award programs, so innovative thinkers can use their grant towards building prototypes and even an initial production run. About Moon Labs<a href="https://www.moon.ai/" rel="noopener" target="_blank">Moon Labs</a> is a medtech startup from Trondheim, Norway, developing an unobtrusive, wireless &amp; affordable hospital patient monitoring system. The Evo System has three elements: The Evo Sensor is a small disposable bio sensor which fits comfortably behind a patient’s ear, measuring heart and respiration rate and oxygen saturation continuously for up to five days; the Evo Gateway transmits this data to a patient’s electronic journal; and finally the Evo Central software enables doctors and nurses to track multiple patients’ vital signs over time and calculates early warning scores to highlight any health concerns.

A potentially life-saving monitoring system for hospital patients on general wards is one step nearer to reality thanks to Protolabs’ European Cool Idea Award.

Moon Labs Evo System - Helping a Life Saving Idea Become Real

Reducing Risk Through On-Demand Manufacturing

Strategic management of your manufacturing supply chain is critical during product development and life cycle planning. This white paper illustrates how on-demand manufacturing can be used to reduce financial risk and accelerate speed to market through the implementation of supply chain safeguards.

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