Advanced technologies for more competitive medical device manufacturing

How contract manufacturers solve challenges with state-of-the-art equipment and expertise

By Henri Asselin, Beacon MedTech Solutions

Medical device manufacturing is complex. Today’s manufacturers face lengthy development cycles, low production volumes that drive up cost, and the sometimes-unpredictable need to rapidly scale production to meet demand.

Medical device contract manufacturing organizations (CMOs) often seek a competitive advantage through long and nuanced business cycles, delivering precision components to customers that accelerate their speed-to-market.

State-of-the-art technologies increasingly help these organizations deliver high-quality products on time and on budget. The following are areas where technologies give today’s CMO a competitive advantage.

Integrating precision medical injection molding technologies

Investing in injection molding technologies is more than just a decision of what thermoplastic injection molding press meets your needs. Traditional injection molding now includes new, innovative technologies like automation and robotics to accelerate success. These evolving technologies enable more rapid production of complex parts with consistent quality, while also empowering teams to complete more high-value, non-repetitive tasks.

Before CMOs can seek a competitive advantage through automation, they first must evaluate the evolution of traditional injection molding technologies that support niche, complex processes. For example, vertical presses combined with press-side automation to place inserts into tools for complex insert molding applications can ensure consistency and quality across all parts. Additionally, liquid silicone rubber (LSR) presses with automatic material feeding systems accommodate many materials and colors to minimize defects and waste.

With the right technologies in place, CMOs can evaluate how automation can help them uplevel quality, speed and efficiency. By incorporating three-axis robots, for example, CMOs can speed cycle times through the automated placement and removal of parts. End-of-arm tooling (EOAT) allows for greater flexibility on the line, picking parts and moving them to conveyors, and is often supported by in-line automation that can quickly advance parts from the molding press into secondary processing. These technologies not only increase speed but can also minimize any risk of human error.

Advancing quality standards to meet evolving needs

To remain competitive, quality is a non-negotiable for CMOs and medical device manufacturers. A robust, dedicated quality function plays a key role in device manufacturing, utilizing a range of technologies for measurement, testing and validation of product requirements. Enterprise technologies like a quality management system (QMS) can support a strong phase gate new product introduction (NPI) process to help drive internal and external alignment.

During the NPI process, contract manufacturers and OEMs work together to confirm specifications and minimize rework. CMOs with investments in simulation software and prototyping tools can address design for measurement (DFMe) early in the process to drive long-term success.

With a QMS in place and the right upfront investment in quality, CMOs can seek opportunities to build out a strong quality practice through sophisticated metrology equipment, such as high-accuracy coordinate measurement machines (CMMs) and vision inspection systems, as well as the right talent to help embrace a quality culture.

Additional on-site equipment dedicated to quality can increase the efficiency of supply chains and quality assurance in finished products. For instance, capital assets like driers, refrigerators and moisture analyzers allow manufacturers to maintain and prepare materials in optimal conditions, maximizing return on investment.

Cross-program technology investments

When looking to leverage technology to remain competitive in a highly regulated market like medical devices, identifying opportunities to invest in flexible and adaptable technologies to share across programs and applications is critical to driving long-term ROI and success.

This may include mechanical testing equipment; precision leak testing equipment and fixtures; automated static cleaning for components; and automation, robotics and EOAT.

With speed-to-market remaining a top priority, CMOs can easily tap into the competitive advantage that these technologies bring.

Technology-forward approach to collaboration

CMOs continue to invest significantly in technologies to meet demand for specialized products and capabilities. These technologies are supported by investments in continuous learning to remain competitive in the medical device market.

Through ongoing education in Lean Six Sigma practices, geometric dimensioning and tolerancing (GD&T), statistical techniques and specialized equipment and materials, manufacturers equip their organizations to support successful product launches.

From engineering and automation to molding and assembly, contract manufacturers constantly integrate new technologies in their operations to increase efficiency and reliability. Ongoing investment in state-of-the-art automation, production and quality technologies helps CMOs and OEMs get to market faster, on budget and at the quality today’s patients and consumers expect.

Henri Asselin is VP of engineering and technology at Beacon MedTech Solutions, where he leads the engineering team and plays a critical role in driving program management, tooling and automation efforts that incorporate new technologies, process, and customer-driven trends. He has more than 25 years of experience in manufacturing operations, working alongside customers to advance groundbreaking solutions and new program success.

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The opinions expressed in this blog post are the author’s only and do not necessarily reflect those of Medical Design & Outsourcing or its employees.