Ensuring manufacturing productivity and component compliance is a delicate balance for pharmaceutical devices. Metal pressed components in particular need to be commercially friendly and produce high-quality outcomes, all the while minimising lead times and showcasing high productivity.
In order to achieve each of these outcomes and ensure components meet strict medical compliance requirements, there are a number of design considerations that need to be taken into account.
In this article, we will go over six key design considerations that can optimise metal pressing production lines. From selecting the right material and packing methods to performing in-depth finite element analysis, we will outline the key steps to ensure high manufacturing productivity without any compromises.
1. Material selection
The choice of material is a critical factor that determines both the performance and manufacturability of the metal pressed components. Stainless steel, for example, showcases a balance of corrosion resistance, strength and durability, making it a common choice for many pharmaceutical devices. That said, its toughness can be too much for certain tooling, leading to more frequent maintenance that can affect lead times and efficiency. Understanding the right materials for the right application can bring a balance of component performance and manufacturability to maximise operational efficiency.
2. Packaging methods
Proper packaging methods are essential to protect components during transit and storage, preventing damage and particulate contamination. Reels, trays and bespoke packaging solutions each serve different purposes. Reels facilitate easy feeding of components into pressing assembly lines, whereas trays are ideal for delicate parts that need to remain separated to avoid damage. The key to ensure commercially-friendly manufacturing is to tailor the approach to specific customer requirements, ensuring that components are both protected and easily accessible during assembly.
3. Quality control and part inspection
Maintaining a high standard of quality is critical in pharmaceutical manufacturing to ensure devices pass strict medical trials. Implementing robust quality control measures and part inspection processes directly reduces rejection rates and improves overall quality outcomes.
- In-line camera inspection: Automated visual inspection systems can detect defects in real-time, ensuring only compliant components proceed to the next stage of manufacturing.
- Manual inspection: Complementing automated systems with manual inspections can catch any issues that might be missed, providing an extra layer of quality assurance.
4. Finite element analysis
Finite Element Analysis (FEA) is an invaluable tool for predicting the performance and longevity of metal pressings under various conditions. By performing stress analysis, manufacturers can determine how a component will react under different forces, optimising the design for durability. Cycle testing simulates repeated use to predict the number of cycles a component can endure before failure, which is particularly crucial for parts like clips or springs that undergo constant use. FEA helps in ensuring that the components meet performance requirements and predicted lifespan to enhance their overall quality and end user experience.
5. Choosing the optimum pressing method
Selecting the right production method is crucial for achieving efficiency, uniformity and cost-effectiveness in metal pressing manufacture. Two of the most effective methods for producing high-quality metal pressings and stampings are progressive die stamping and slide forming.
- Progressive die stamping: Ideal for high-volume production, it offers precision and consistency by feeding metal through a series of dies, creating complex parts in a single continuous process with minimal waste.
- Slide forming: Effective for intricate parts with multiple bends, it uses horizontal tools to form metal, allowing for complex geometries and quick tooling adjustments, making it suitable for versatile and precise component production.
6. Integrating the right tooling
Investing in the right tooling is essential for maintaining precision and quality in metal pressing manufacturing. Custom tooling, designed specifically for certain pressed components, ensures precision, uniformity and efficiency in production. Regular maintenance of tools is also crucial to keep them in optimal condition, reducing downtime and ensuring consistent quality. By focusing on the right tooling solutions, it becomes simple to enhance the precision and efficiency of production processes, leading to better quality outcomes and reduced manufacturing costs.
Get industry-leading expertise with Advanex Medical
Achieving high-quality outcomes, enhanced manufacturing productivity and complaint pressed components involves careful consideration at each stage of the process. Whether it involves selecting appropriate materials or introducing a robust quality control, metal pressing production requires in-depth knowledge to get each that perfect level of high-quality output. To help achieve this, you need an experienced partner that can enhance manufacturing efficiency, reduce lead times and ensure high-quality outcomes.
Advanex Medical is the ideal partner to achieve these goals. With our expertise in material selection, advanced quality control systems and sophisticated analytical tools, we can ensure every component meets the highest standards. Our global presence, commitment to sustainability and innovative approaches leaves us as a leading choice for pharmaceutical companies seeking to optimise production and achieve exceptional quality. By partnering with Advanex Medical, you can rely on a dedicated team to deliver excellence throughout the production lifecycle.
To find out how we can provide this same service for you and your medical production lines, get in touch with one of our experts.
