When assembling plastic medical devices, manufacturers can connect parts using screws, glue, clips, or welds. However, to adhere parts most securely, welding is the preferred solution. Welding has several advantages over glue or clips. It creates a stronger bond by melting the plastic parts together rather than trusting a surface adhesion or risking breaking the clip. Welding is also less expensive than other assembly options because there are no added materials needed, such as glue or screws. Additionally, welding can be used for small parts, it’s faster and lightweight, and the seam is leak-tight.

PIA Automation, specializing in building tailor-made assembly machines for mid- and high-speed assembly of complex medical devices, was looking for welding technology to complete a secure and reliable plastic assembly for a customer’s new machine. PIA Automation decided to go with Emerson‘s welding solution that achieved a dedicated requirement in short cycle time, high repeatability, and reliability. 

Taking a process-neutral approach
There are several factors to consider when building welding solutions, including the size and dimension of parts, materials and design specifications, as well as specific requirements such as leakage, vibration, and chemical resistance. The dimensions of injection-molded plastic parts in medical devices can vary from the top of the tolerance field down to the lowest dimension. When welding these kinds of parts, it can affect cycle time and make maintaining consistent quality, which is essential for medical devices, a challenge.

To make it possible for their customer to achieve a high level of product quality every time while meeting customer demand, PIA Automation wanted the welding technology it was designing to achieve the shortest cycle time, offer high repeatability, and be a reliable process. Machines with short cycle time can operate with greater productivity, reducing cost per produced part, while those with high repeatability ensure the same result and quality from product to product. Reliable processes require fewer quality checkups and destructive tests, resulting in less cost. Emerson understood that highly precise technology would be required to meet these goals.

With this in mind, Emerson took a process-neutral approach to help PIA Automation identify the most effective solution. Emerson conducted dedicated laboratory testing to solve this challenge and identify tailored tooling with the right parameter setup.

To determine which technologies and what parameters were necessary to achieve the desired result, Emerson tested multiple tools and simulated various welding parameters to prove the concept. During these welding trials, Emerson and PIA Automation identified the most effective tailored welding tools and parameters: the Branson GSX Ultrasonic Welder and 2000Xc Series system.

Meeting exacting requirements with a combined solution
This combination of Branson GSX Ultrasonic Welder and 2000Xc Series technologies gives machine operators full control of key process parameters, high repeatability and FDA 21 CFR Part 11 capability. The combined solution also helps optimize utility consumption and reduce costs. Each technology has distinct design features that benefit manufacturers in multiple ways.

Designed for the assembly of small and intricate plastic components, the Branson GSX Ultrasonic Welding Platform is an advanced servo mechanical drive welder for low-force welding that provides precise control for faster, repeatable welding performance. Intuitive and flexible, it’s designed to optimize and ensure high-quality welds while helping manufacturers meet project timelines and deliver expected returns on investment.

Its easy-to-use, smart welding technology helps get product to market on time and on budget, while its control and position accuracy ensures that manufacturers can perform consistent, faster, high-quality welds for a wide range of plastic parts, even for the most challenging applications. Its embedded expertise simplifies operation, improves production efficiency and reduces labor and operating costs.

Designed for maximum process control, the Branson 2000Xc Ultrasonic Welder locks in the welding process with fully electronic weld settings, hierarchical password protection and Ethernet connectivity capabilities. The 2000Xc combines precise and consistent high-quality welds, fast cycle times and the process control needs of today’s manufacturing environment. Its secure process controls and detailed weld data are designed to meet the global compliance, traceability and security needs of today’s medical, automotive, and business and consumer electronics markets. This system is designed to ensure compliance with manufacturing regulations, including ISO 13485 and medical FDA 21 CFR part 11.

Achieving full process control and high repeatability
Emerson helped PIA Automation assess its application challenges and goals, select proven technology, then install, calibrate, and set up the system according to the machine environment to reach maximum performance.

Emerson experts provided support, extensive knowledge and a process-neutral approach to application development and helped PIA Automation achieve a reliable solution. Emerson understands that each application has its own particular properties, characteristics, part geometry and customer requirements. Understanding advantages and limitations of each process and working closely with machine builders is crucial to develop and implement a solution that works best for the application.

Once selected, Emerson installed, calibrated and set up the system according to the machine environment to reach maximum performance. Ultimately, the combined solution of the Branson GSX Ultrasonic Welder and 2000Xc Series system helped PIA Automation design a machine for its customer that optimizes utility consumption and reduces costs.

Strong partnerships build strong bonds
When creating machines that assemble medical devices, it’s essential to choose the right technologies, especially joining equipment, to achieve consistent quality and maximize operational efficiency. However, to get there most effectively requires the right partner and a process-neutral approach.

A process-neutral, problem-solving approach paired with industry leading expertise, services and innovative portfolio can help companies find the most effective solutions to solve their challenges and achieve their most ambitious goals. By not being fixed to one technology, companies can screen their applications, with all their requirements, to choose the best technology for each of their applications. What’s more, companies don’t have to take on project risk by selecting only one technology.

Through its partnership with Emerson, PIA Automation built a welding solution that meets its customers’ exact assembly needs — as well as strengthens its own bonds.

Emerson
www.emerson.com 

PIA Automation
www.piagroup.com