Metal pressings are a fundamental component in the manufacturing of medical devices, playing a critical role in the creation of precise, durable and reliable parts. These pressings involve shaping metal sheets into specific forms through processes such as stamping, bending and cutting, ensuring that each part meets stringent medical specifications.
Uniformity in these metal pressings is paramount to ensure that each component fits perfectly and functions as intended, which is essential for the efficiency of medical assembly lines and for medical devices to pass verification. In this article, we will explore the different ways to ensure this uniformity across different metal pressed components and Advanex’s expertise in achieving this across a range of designs.
The benefits of batch-to-batch uniformity
Easier assembly
Uniform components streamline the assembly process, reducing time and labour costs. When each part meets specification, the risk of issues appearing during assembly is almost completely eliminated, allowing for a smoother and faster production line and lead times.
Higher manufacturing yields
Consistency in manufacturing reduces the likelihood of defects. Uniform metal pressings ensure that each component fits and functions as intended, leading to fewer rejections and higher overall quality in the final product.
Reduced costs
Efficient use of materials is achieved through uniformity, which directly impacts sustainability efforts. By producing consistent parts, manufacturers can minimise scrap rates, thereby reducing waste and contributing to more environmentally friendly practices.
Choose the best pressing process for your component
There are a number of metal pressing processes available. Some are better suited to medical device components than others. Having an understanding of these pressing techniques is crucial to ensure uniformity early on in the production process. For example, some forms of pressing are more stressful than others, which require chemical-rich lubrications to achieve complex shapes.
Progressive die stamping
Progressive die stamping involves a series of stations that progressively shape flat sheets of metal into components. A bespoke die is created which includes different stages of the shaping process across its design. When sheet metal is fed into the press, it progressively goes through each station to autonomously produce pressed components.
Progressive die stamping is perfect for components requiring multiple stages of shaping and cutting. It is particularly effective for parts that need high repeatability and precision to ensure uniformity. That said, progressive die stamping can lead to increased scrap as the process requires holes to be stamped out in order to align with the specific stations.
Slide forming
Slide forming involves four individual sliding dies that bend metal components into specific shapes. These dies are at right angles to one another, each performing a controlled action to produce the final stamped component. Instead of sheet metal, metal slit coils or coils of wire are fed into the slide forming machine to create complex shapes.
Slide forming is best suited for bespoke components and those with complex geometries to maintain uniformity. Additionally, it is ideal for creating detailed shapes with minimal material waste, showcasing around 30% less waste than progressive die stamping. On the other hand, slide forming machines are less flexible than progressive die stamping, and take longer to set up and switch dies when facing multiple manufacturing lines.
The importance of bespoke and high-quality tooling
One of the crucial aspects of ensuring uniformity in metal pressing is to use bespoke and high-quality tooling. By using dies and presses that are specifically designed for the component, the chances of producing the exact specifications are far more likely. Moreover, using low quality tooling can lead to defects, breakdowns and burring. This highlights the importance of properly designed and maintained tools to ensure that every part is consistent, up to standard and pass verification stages. At Advanex Medical, we prefer to produce our own tooling in-house. This minimises downtime, ensures that tooling is optimally designed for the pressing process and allows us to take complete ownership of quality outcomes.
Partner with an experienced metal pressings manufacturer
Having an experienced manufacturing partner is invaluable in ensuring uniformity and quality in metal pressings for medical devices. This partner brings extensive expertise and a commitment to good manufacturing practices, which are essential for success. They can provide guidance on maintaining a tidy workspace, thorough documentation and excellent maintenance practices. These principles ensure that every aspect of the manufacturing process is optimised for quality and efficiency. Additionally, a reliable manufacturing partner can offer bespoke tooling and die set services to improve the longevity of your production lines while maintaining high levels of output.
Think Advanex Medical for your trusted partner in medical component manufacture
Ensuring uniformity across metal pressings in medical assembly lines is crucial for improving efficiency, reducing rejection rates and minimising scrap rates. By selecting the appropriate pressing process and using bespoke, high-quality tooling, you can produce consistent, high-quality components. But doing this is easier said than done, hence why partnering with an experienced metal pressing manufacturer is also essential for achieving the desired uniformity and quality.
Advanex Medical is the ideal partner for metal pressings and medical manufacturing, bringing extensive expertise and commitment to good manufacturing practices. We adhere to stringent standards, ensuring that workspaces are tidy, documentation is meticulous and equipment is excellently maintained. This dedication to excellence and innovation enables us to develop manufacturing processes that directly meet the needs of our customers, providing high-quality, uniform metal pressings essential for medical devices.
With Advanex, you can be confident in the reliability and performance of your medical components. Connect with our experts who are ready to help you navigate the complexities of medical device production and ensure your products meet the highest standards of quality and efficiency.
