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In appreciation, we’re offering an exclusive discount to our TIPS subscribers: half off a tooling package with every Magnum purchase!! A $4,000 savings! See below for details!!
This issue presents a Case Study in which Cath-Tip’s Development Process simplified a difficult part’s production process and tripled its yield rate! Read how we helped this customer, then tell us how we can assist you.
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One Tooling Package produces one part application in semi-automatic production on RF Magnum Machines.
Semi-Auto Tooling includes:
- Carbide Tipping Die
- Die Mounting Block
- Precision Mandrels & Holders
- Clamp Assembly
- Nest Assembly
- Heating Coil
- Engineering Tool Design & Parameter Development time
(Not limited to any number of machine purchases. Not available with other discounts. Not applicable to prior purchases.)
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Catheter manufacturer increases yield rate and simplifies their process by using Cath-Tip’s process development services
PROBLEM: A customer was having trouble producing tips of PTFE tubing and struggled to achieve the needed quality and consistency of parts and efficiency of process. PTFE is a difficult material to form and trim due to its mechanical properties and broad working temperature.
GOAL: Parts were being made in a three–step process, while the customer dared to dream that one day they could be made in a single step.
SOLUTION: Cath-Tip was enlisted to assess the current state and determine whether improvements might be made. Applying the Cath-Tip Development Process, a method was developed by which the part is necked down, tipped and trimmed in a single step – consistently, and at a rate of 6 parts per minute.
CHALLENGES: PTFE behaves like a thermoset material and doesn’t melt and flow like other thermoplastic materials commonly used in catheters. PTFE also has high temperature resistance properties.
STEPS: In order to neck and trim the tip forming force of approximately 40 lbs was required. To achieve this relatively high amount of force the motion carriage of a Cath-Tip® RF tipping machine was modified by way of incorporating extra back-pressure springs. In addition, the feed rate was increased incrementally to settle at 3 inches per second.
These modifications were not enough to be able to get a clean trim – flash was still present. The amount of force being applied to the material caused the tubing to buckle. In order to eliminate the buckling, the amount of pressure being applied to the gripper was reduced to 35 psi, allowing the tube to slide back before it could buckle.
Once the issue of buckling was addressed, the matter of trimming remained. It was noted that running at higher temperatures caused the material to relax and become stretchy and difficult to trim. Power output was reduced to about 28% and resulted in improved trim.
The final step to the fine tuning process was to adjust the coil position on the die in order to get the best looking tip possible.
As validation, 50 sample parts were run consecutively and with no rejects. The customer will now be able to produce parts in one simple step and in 1/3 the time.
Cath-Tip cares about the success of our customers and we are here to support you.
Contact us about your project: email firstname.lastname@example.org or call 1-435-628-1775