IML Syringe Barrel
Judges' Award
Brand Owner: N/A
Designer: Tech Mold Inc./CBW Automation/Mold-Masters
Machinery Manufacturer:CBW Automation/Milacron LLC
Materials: PolyOne Corp./Inland Label
Molder: N/A
Moldmaker: Tech Mold Inc.
Product Description:
The Preffilable Syringe Barrel using the IML process incorporated several unique design elements not traditionally used in the mold design for a syringe barrel in order to accommodate the IML molding/manufacturing process which includes labels, exacting label placement through the use of robotic automation, and controlled material flow to avoid core shift and label disruption. The purpose of this pilot project is to prove out the IML process using new hot runner/side-gating technology, unique mold design, label graphics and intellectual property protection (holographics)technology, cut-in-place robotic label placement in the 16-cavity mold that can operate in a high-speed production setting using the IML process for medical syringe applications.
Why is the product innovative?
In-Mold Label Technology: Typically, the dosage markings are either pad or offset printed onto the plastic barrel or printed on self-adhesive polymer labels and placed on the barrel - all requiring second operations and additional handling. The small outer diameter of the barrel and the registration for the dosage markings created a challenge for the accuracy of the label placement. To solve this, the mold was designed with an innovative "stop" near the top of the barrel to aid in accurate label placement - within .010. The roll-fed labels contain high-impact graphics and an anti-piracy feature - a holographic NPE logo that can only be seen under certain lighting - designed by the label manufacturer. The labels are cut-in-place at the press using a technology developed by the automation machinery manufacturer. Mold Design: To accommodate an in-mold label with dosage markings, the syringe barrel has a lip (stop)designed near the top of the barrel to capture the label in an exact position as the material flows in a straight part up the barrel from the base to the tip. Design had to accommodate new hot-runner/side-gating technology used in this project. Gating Considerations for IML: Typically, a syringe barrel will be either double-gated on each side of the flange at the base of the barrel or in some instances single-gated at the flange, which has a thicker wall section to permit better material flow. The material will then flow around the flange and up the barrel in a straight path in such a way that the material won't disturb the label. This is a critical element because the label contains the dosage registration marks to ensure that a proper dose is administered to the patient. The exact alignment of the dosage registration around the circumference and barrel length was critical to the success of the use of IML in this application. New Hot Runner Technology: Using a new side-gate hot runner system and melt technology, the 16-cavity mold for this project enabled gating into the side of the barrel close to the base (flange), a requirement so that injection has minimal influence on the core and reduces or eliminates core shift. Because the gated area must have a thicker wall section to accommodate material flow, the wall thickness was increased in a circular area around the base of the barrel just above the flange area at the base. Robotic Automation: Each element of this part had to be specifically designed to create a mold that optimizes automation, maximizes the use of the newly developed hot runner/side-gating system and melt technology, and ultimately accommodates high-speed automation typical of the IML molding process.
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