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Surgical Blade Assembly for the Medical Industry

This project is for an existing medical products customer, with whom we've enjoyed a nearly 30-year relationship. They had experienced rapid growth of this product line and came to us for help in finding a way to increase capacity and also hopefully lower costs—a natural fit for a higher cavity mold.

Klann engineers designed a new mold using SolidWorks which doubled the number of cavities to 8. We sourced the building of the mold through one of our trusted Asian mold-making partners at a very reasonable cost, resulting in a positive return on investment for our customer after only 6 months.

The surgical blade assembly is molded and packaged in our dedicated Class 10,000 clean room. The resin is a 10% glass filled natural polypropylene which is molded around a surgical stainless steel blade insert. A blue colorant is blended with the base resin at the machine. We perform SPC on the finished parts, including a pull test on the Tyvek pouch.

Specifications

Component Name	Surgical Blade
Capabilities Applied/Processes	New 8 Cavity Mold Designed by Klann Plastics Clean Room Injection Molding Pull Test Assembly & Packaging Manage Bioburden Test Results
Equipment Used	In house injection molding machine
Overall Dimensions	2.15 Inches Long x .90 Inches Wide
Material	Nat Polypro 10% Glass Filled Colorant Blended at Machine
Typical Operations	Design: Mold designed using SolidWorks New 8 Cavity mold doubled the number of cavities using same mold footprint Manufacturing: This is an insert injection molded part The Plastic is Injection Molded around the Surgical Blade
Standards	Class 10,000 Clean Room No Contamination No Blade Blemishes Pull Test Performed on Tyvek pouch
Project Characteristics	Manufactured using the most cost effective solution The Higher output of our newly designed mold enabled us to meet our customer's higher demand levels