OPC UA  NPE 2024 – What’s in it for the Customer?

“An educational initiative for OPC UA must be launched”

Industry interview with Tony Marchelletta, National Sales Manager Sumitomo (SHI) Demag Plastics Machinery N.A.

Does Sumitomo Demag already offer its customers injection molding machines with an OPC UA interface?
Yes, it has been available in some of our higher-end models for a few years now. Especially those that are manufactured in Europe. Last year, we also added OPC UA to our standard Japanese-built SE-EV-S model, which we mainly sell in the US. It has always had an Ethernet connection, and now we simply transfer the data automatically via the OPC UA interface.

Where does OPC UA offer the greatest improvement over other interfaces?
I think at its core it’s about standardization. Many third-party providers have had a wide variety of plant monitoring systems for decades, but each has its own proprietary way of communicating and transmitting data. For us as an OEM, it has always been a challenge to keep our software engineers and also our hardware engineers up to date so that we always have the right interface for the machine. I think everyone was hoping that we would finally have a common language, a way to communicate not only with the injection molding machines but also with the periphery equipment and automation.What challenges does the widespread of OPC UA face in the USA?
The biggest challenge is the large number of machines that we or our customers have to deal with. Machines come here from all over the world. From Europe, India, Taiwan, China, Japan, Korea. There is no real common ground. Not even in the interfaces. The same applies to the installation of plant monitoring systems or ML systems. They are all still rooted in their respective methods. And then the machines and systems are of different ages. I have customers who operate machines that we built over 30 years ago. They are still mechanically sound. The customer wonders why they should replace them. It’s a different story with brand new machines. Ten years ago, I had a customer who wanted to use OPC UA in his plant. He was very enthusiastic about the possibilities and wanted to be prepared for the future. But he also had the luxury of building a brand new plant network. Ten years ago, this customer was quite alone in his knowledge. Another obstacle to the slow spread of the new interface is that although there is now a lot of talk about OPC UA, hardly anyone can actually do anything with it. The benefits are not yet apparent.

Will the major control system providers also jump on the OPC UA bandwagon?
Definitely. If they don’t, it could be disastrous for them. Sooner or later, OPC UA will become the common language. Not everyone in the world speaks Siemens, not everyone speaks Rockwell, but everyone will be able to communicate with OPC UA. Control manufacturers will still be able to offer unique technologies. I think there will still be some differentiators that can protect their interests.

How likely is it that the acceptance of OPC UA will increase in the United States in the medium term?
It would make our lives as OEMs easier if OPC UA were already a universally accepted protocol. But I think it will still take some time. There are many systems that are simply not able to communicate with OPC UA. There is still a lot that is unknown, especially in the North American market. Everyone has heard of OPC UA, but no one really knows what it is. What can it do? What can you do with it?

I think there definitely needs to be a big educational initiative here. The first step would be to inform the plant managers and motivate them to get involved. But they often don’t have the employees they need. It’s a lot of work, especially when many devices have to be connected to the one protocol.

That’s why it will be a while before OPC UA is widely implemented at plant level here in North America.

Could the NPE be a good place to start with the education initiative?
Yes, absolutely. It’s the definitive show in North America for our industry. There will be a lot of visitors, the largest audience is here. That’s why the NPE is a great platform and a great channel to spread the message of OPC UA. Of course, you still have to go to the companies later and explain to the people there in personal discussions how they can integrate OPC UA into their plant system in concrete terms. But the start has been made with the NPE.

www.vdma.org

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Did You Know That Rice Bran Waxes Can Replace Carnauba Waxes?

Carnauba wax, derived from palm leaves, has long been considered as the gold standard for delivering key properties like hardness, scratch resistance, and gloss in coatings. However, with increasing supply constraints and sustainability concerns, formulators are actively seeking alternatives1 . At Clariant, we recognize the need for alternatives driven by customer demands as well as our responsibility to address environmental challenges. We strive to make a meaningful impact in the industry all while maintaining our focus on meeting the diverse needs of our customers.

The power of Licocare  rice bran waxes
Licocare RBW Vita offers an innovative bio-based solution that retains the shine, durability, and formulation potential associated with carnauba while aligning with sustainability preferences. This renewable carnauba alternative achieves exceptional performance qualities through 100% plant based sourcing.

Our upvalued rice bran waxes offer high-performance solutions at the same time as addressing the key sustainability mega-trends transforming the coatings industry. They are not just renewable based, but also non-food competing, contain no microplastics or PFAS chemicals, and have a remarkable renewable carbon index exceeding 98%. Clariant’s rice bran waxes can already be found in automotive coatings, furniture coatings, and protective coatings such as in cell phones.

Its lighter color enables flexible adaptation across color-sensitive applications. Produced through controlled industrial processes, our consistent quality avoids production adjustments needed with natural waxes. With a broad portfolio and wide variety of solutions, Licocare RBW Vita offers formulators a choice of characteristics like polarity, hardness, and melting point to select the optimal product for their care products, emulsions, coatings, and plastics.

Licocare RBW Vita simplifies the substitution in existing carnauba-based coatings thanks to an extensive portfolio offering a wide choice of characteristics (polarity, hardness, drop point, particle size) to fit diverse applications like care, emulsions, coatings, plastics, and many more. You can expect high performance in the following key areas:
• Outstanding scratch resistance and slip
• Excellent formulation stability
• Neutral transparency that prevents discoloration

“With Licocare RBW Vita, we bring meaningful, high-quality solutions to coatings applications while reflecting our sustainability values. These bio-based rice bran waxes represent the future of coatings.”

Whether seeking to overcome supply chain hurdles or improve sustainability, Licocare RBW Vita unlocks the next generation of renewable coatings while minimizing any necessary compromises. Carnauba-like functionality and beyond is possible with rice bran wax.

Ready to elevate your next formulation?
Visit our dedicated rice bran wax landing page to learn more about the power of Licocare RBW Vita and contact our experts, who will help you achieve sustainable success.

www.clariant.com

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Micro Molding and the Future of Biomedical Applications

Paul Runyan, VP Sales & Marketing, Accumold

In the dynamic medical field, micro molding has increasingly become the foundation for innovation, particularly in the creation of cutting-edge biomedical devices. This article explores the transformative impact of micro molding within the biomedical industry, and highlights how the unparalleled precision, scalability, and customization offered by micro molding are paving the way for future breakthroughs in patient care. Furthermore, we examine how these technologies facilitate the miniaturization of devices, making procedures less invasive and more efficient, thereby significantly enhancing patient outcomes. The insights presented underscore the critical role that micro molding plays not only in current medical device development but also in shaping the future landscape of healthcare technologies.

MICRO MOLDING

Micro molding is a specialized manufacturing technique that involves the production of extremely small components, crafted from broad palette of different polymers, and characterized by their high precision and meticulous accuracy. The significance of micro molding is highlighted by its critical role in the development of miniature medical devices featuring intricate shapes and made from advanced, high-performance materials, which are increasingly required for innovative healthcare applications. These applications include, but are not limited to, tiny implants, sophisticated surgical tools, and advanced diagnostic equipment. This capability to fabricate small-scale, complex components is essential as it supports the advancement of medical technology and enhances the functionality and effectiveness of medical treatments.

The primary advantage of micro molding lies in its exceptional precision. This technique is essential for producing medical devices such as stents, catheters, and wearable sensors that must meet not only specific dimensional requirements but also stringent health and safety standards. Micro molding achieves this by allowing the production of components with ultra-fine tolerances, often in the range of just a few microns, and it does this repeatably, there being a demand for zero failure rates in safety critical applications.

Additionally, scalability plays a crucial role in the widespread adoption of micro molding for medical applications. Once a mold is precisely engineered, manufacturers can rapidly produce large quantities of components. The capability to scale up production means that components can be manufactured in the thousands or millions, facilitating quick distribution and significantly reducing the cost per unit. Such scalability is particularly advantageous for the production of high-volume items like medical diagnostic test strips, which require consistent quality and reliability.

Another significant benefit is the extensive customization possibilities micro molding allows. The process can be finely adjusted to create unique geometries tailored to specific medical needs. This level of customization not only applies to the physical shape of the components but also extends to the choice of materials used, enabling the production of devices that meet exact requirements for flexibility, biocompatibility, or biodegradability. By combining these customized solutions with micro-level precision and scalability, micro molding stands out as a transformative technology in the biomedical field, supporting innovations and improving patient care

IMPACT ON PATIENT CARE

The miniaturization of medical devices through the use of micro molding is significantly transforming patient care. By reducing the size of these devices, they become less invasive and more comfortable, enhancing patient comfort and potentially accelerating recovery times while minimizing the risk of post-operative complications. For example, smaller implants can be placed through less substantial incisions, minimizing tissue damage and promoting quicker healing.

Additionally, micro molding allows for the seamless integration of sophisticated electronic components within medical devices. This advancement heralds a new era in personalized medicine, where devices are not only capable of passive tasks but can actively monitor vital signs, administer medications, and dynamically adjust their operations based on real-time changes in the patient’s condition. This capability could lead to highly individualized treatments and interventions, further improving medical outcomes and patient well-being.

PIONEERING TECHNIQUES AND INNOVATIONS

Companies like Accumold are leading innovators in the field of micro molding, consistently pushing the limits of what can be achieved in manufacturing tiny, precise components. Accumold excels in creating micro-molded plastic parts that are used across various critical sectors such as medical, the company utilizing proprietary micro molding techniques to manufacture parts that are not only smaller than a grain of sand but also feature intricacies that measure just a few microns across.

The sophistication of Accumold’s operations is reflected in the company’s in-house production of specialized micro tooling designed specifically for the vagaries of micro-scale production. The company also uses advanced polymers that are tailored to the specifics of a particular application, ensuring that each part meets rigorous standards of quality.

Accumold’s pioneering work in the area of micro molding is especially significant in the medical industry, where its advancements are making way for the development of more complex, reliable medical implants and devices. This technological progress is crucial for the evolution of medical treatments and equipment, setting new benchmarks in the healthcare sector and beyond. Their ongoing commitment to innovation and excellence in micro molding continues to open up new possibilities and applications, driving forward the capabilities of miniature manufacturing technology.

One such is the recent announcement that Accumold has found a way to micro mold thin wall cannulas in very high volumes. Micro injection molding enables the creation of intricate and consistent cannula designs with precise wall thickness control. It eliminates the need for separate extrusion, tipping, and gluing steps by producing the entire cannula in a single mold, enhancing product reliability and reducing the risk of defects. This approach not only improves the quality and reliability of the cannulas but also offers a more scalable and cost-effective solution for meeting the demands of high-volume production in the medical industry. Micro molding cannulas at volume with an outside diameter of 0.035”  (0.889 mm), an inside diameter is 0.027” (0.6858 mm), and a wall thickness of 0.004” (0.1016 mm) is routine at Accumold.

FUTURE DIRECTIONS AND TECHNOLOGIES

The future of micro molding in biomedical applications looks highly promising, with several innovative directions that could significantly impact medical treatments and patient care. One key area of interest is the use of biodegradable polymers, which are already used in — but are poised to revolutionize — the field of implantable medical devices. These polymers can be used to create temporary implants or scaffolds that naturally dissolve within the body once they have served their intended purpose. This capability effectively eliminates the need for a subsequent surgical procedure to remove the implants, thereby reducing the overall risk and discomfort for patients.

Furthermore, the integration of nanotechnology with micro molding represents another exciting frontier. By embedding nanoparticles or nanostructures into the molded components, manufacturers can dramatically enhance the functionality of these devices. For instance, the addition of nanoparticles can increase the electrical conductivity or thermal resistance of the implants, which can be crucial for devices that require these properties to function correctly. Additionally, incorporating nanostructures can lend antimicrobial properties to the implants, greatly reducing the risk of infections post-surgery and during the healing process.

These advancements not only aim to improve the quality and efficacy of medical treatments but also strive to reduce the overall healthcare costs by minimizing the need for additional surgeries and by extending the longevity and functionality of implantable devices. As research continues to advance in these areas, the possibilities for new applications and improvements in micro molding technology are virtually limitless, promising a new era of sophisticated, tailor-made biomedical solutions that cater directly to the evolving needs of patients and healthcare systems worldwide.

CHALLENGES AND CONSIDERATIONS

Despite its numerous advantages, micro molding also confronts several challenges. The exceedingly precise nature of this manufacturing process necessitates advanced design strategies and meticulous quality control measures to guarantee that every component adheres to the required specifications. Furthermore, the creation and integration of innovative materials and processes demand substantial investment in research and development. Obtaining regulatory approval for these new methodologies can be a complex, time-consuming, and expensive endeavor.

This requirement for continuous innovation and compliance can significantly slow down the speed to market, impacting the overall efficiency and cost-effectiveness of micro molding projects. Additionally, the high level of technical expertise required to implement and manage these sophisticated processes can pose a barrier to entry for many companies, potentially limiting the broader adoption of micro molding technologies in various industries. This all shows the necessity of working with an experienced and expert micro molding innovator like Accumold which can act as your qualified micro molding partner and help you navigate the challenges inherent in the process.

SUMMARY

Micro molding technologies hold a key to future biomedical advancements, offering unmatched precision, scalability, and customization for medical device manufacturing. As the technology continues to evolve, it promises to further revolutionize patient care, making treatments less invasive, more effective, and highly personalized. The ongoing developments and innovations in this field are not just enhancing existing applications but are also opening up entirely new possibilities in the medical sector.

This exploration of micro molding technology underscores its vital role in shaping the future of biomedicine, highlighting both the current capabilities and the potential for future breakthroughs that could redefine healthcare as we know it.

www.accu-mold.com

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