Medical Dip Molding
DipTech Systems® specializes in dip molding and dip coating equipment for medical products. DipTech Systems has been chosen by leading medical device manufacturers to assist from concept design to full scale production equipment. Offering equipment specifically designed for some of the most demanding products, such as long term implant, thin walled inflationary balloon and wire reinforced venous catheters, has established DipTech Systems® as the leader in precision dip molding equipment.
Our experienced engineering staff evaluates each project individually. Capitalizing on our diverse experience with an array of natural and synthetic (organic and solvent) based polymers, we are able to advance projects from the URS (User Requirement Specification) phase quickly to FAT (Factory Acceptance Testing).
Our technical staff can assist your company with quality system management functions, such as the creation of necessary documentation to complete the Design Qualification (DQ), Installation Qualification (IQ), Operational Qualification (OQ) and Performance Qualification (PQ). The majority of our production systems are designed to allow our customers to comply with 21 CFR Part 11 FDA regulations by offering security access, tracking changes and personnel actions made to the programmable operating and process portion of the control system. Additionally, our control software can integrate historical trending and data collection for enhanced quality control compliance.
Research & Pilot Scale
DipTech Systems® offers our Diplomat® series to assist customers with their dip molding and dip coating research & development needs. The Diplomat® series is also appropriately sized to address pilot and small scale production requirements.
Development equipment is often the crucial means to ensure accurate process definition and is instrumental in the production of test and marketing samples, as well as the evaluation of multiple polymers or solutions.
Innovative design has made the Diptech Systems®’ Diplomat® series the recognized leader in dip molding and dip coating development and small scale production equipment.
Precision control of up to five (5) axes of fully programmable motion is integrated with other critical features, including automated tank temperature control, solution mixing, pumping system, convection drying, thermal, ultraviolet and infrared curing and many more.
Load capacities offered in our HD series allow for product or mold payloads in excess of 45 Kg. (100 pounds).
Optimized by one of DipTech Systems®’ advanced control systems, the Diplomat®series can be controlled by a standard desktop or laptop PC or by a variety of PLC brands offered to match your company standards. The Visual Basic PC controlled platform offers:
- Multiple axes coordinated control which allows for precision application of polymer or other coatings and elimination of air entrapment for the most challenging mold or product geometries.
- Adaptable for multiple process and product characteristics, the Diplomat® series will support various polymers and has been specifically designed for use with solvent based dip molding and dip coating chemistry.
- Tested and dependable, the Diplomat® series’ robust design will offer years of dependable service.
Please contact DipTech Systems® to review your product or process needs and allow us to generate a customized research or pilot scale system for your project.
Production
Production equipment options include both high volume continuous chain lines and precision batch systems. DipTech Systems® offers the expertise to assist in the selection of the proper equipment style and size to optimize your project success. Focusing on the high demands that are related to production equipment, DipTech Systems® designs for continuous operation with minimal down time and incorporates modular design to aid in optimizing MTTR associated with most wear item replacement. DipTech Systems®technical team can assist you with the development and implementation of validation for your customized equipment, including Installation qualification (IQ), Operational qualification (OQ) and Performance qualification (PQ).
High Volume Chain Line
High volume continuous chain dip molding systems, often referred to as drag chain lines, offer high volume capacities for narrow product families with defined process parameters. Typically utilized for aqueous based polymers, continuous chain lines can be considered for some solvent based products. High volume continuous motion or chain lines are capable of producing over 1000 pieces per minute. Because the line transports the molds through the system at a constant speed, each station length sets the timing available for the process being performed at that station. To assist in defining the process requirements necessary for the development of the high volume production equipment, DipTech Systems® offers R&D equipment capable of simulating the chain line features. Alternatively, we offer assistance in our in-house lab by working with the customer to define these important process requirements.
Batch
Batch or robotic style equipment offers the ability to repetitively perform complex manipulations and provide variability for large arrays of product sizes, geometry and polymers.
Batch dip molding systems offer lower to intermediate volume capacities and are widely utilized with both aqueous and solvent based solutions. Their design specifically lends this technology to solvent based solutions, as key stations can be contained in full enclosures with relative ease for containment of solvents and control of solvent levels and environmental conditions.
Batch systems allow process parameters to be varied through the control system as chemistry or product changes dictate. We strive to provide sufficient range in control parameters to limit the need to alter the equipment design for even large process changes.
Batch systems offer greater flexibility for confined floor space or ceiling height limitations and have the ability to be oriented in numerous configurations.
Batch systems also permit ready access to the product or tooling by the operator during the process, which, in the case of complex moldings such as some Foley or venous catheters, is a necessity to introduce key features such as the lumen wire, reinforcement wiring or balloons to the molded product.
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