Case Description
Client Background
A leading medical infusion consumables and in vitro diagnostics (IVD) device manufacturer, developing a series of high-precision polycarbonate (PC) Luer lock connectors for infusion sets, syringes, and tubing assemblies.
Client Pain Points
- Medical-grade PC is sensitive to moisture and high temperatures, increasing the risk of internal stress, bubbles, and yellowing.
- Luer taper and thread dimensions require strict ISO 80369 compliance to prevent leakage and accidental disconnection.
- Maintaining consistent production yields and cleanliness during high-volume manufacturing presents significant challenges.
Customization Process
The customer provides 3D drawings, materials, and quantities - OEM medical mold design - mold manufacturing - Class 10,000 cleanroom injection molding - sterilization packaging - shipment.
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Our Solution
Precision Injection Molding
Utilized fully electric medical-grade injection molding machines with microgram-level metering and closed-loop pressure control.
High-Precision Mold Design
Applied high-hardness mold steel, flow simulation, and nano-level polishing to achieve smooth inner walls and minimize weld lines.
Cleanroom Manufacturing
Conducted injection molding and deflashing in a Class 10,000 cleanroom to maintain cleanliness and reduce contamination risks.
Automated Quality Inspection
Implemented 100% automated optical inspection to detect dimensional and surface defects and support consistent product quality.
Results and Achievements
Met dimensional requirements and passed leak testing on the first attempt.
Achieved stable yields above 99% for efficient mass production.
