Plastic injection mould disposable syringe

In addition, our company has established cooperative relationships with plastic raw material suppliers, printing manufacturers, etc. to ensure the supply of raw materials and printing quality. Through our rich experience and perfect supply chain, our company can provide customers with high-quality customized plastic injection mould disposable syringe products to meet their specific needs. At the same time, we have 10 years of professional foreign trade service experience, understand the foreign trade process, and better serve our customers. For plastic injection mould disposable syringe products, we can make corresponding plastic parts, which is mainly done through injection molds.

The plastic injection molding process for disposable syringes embodies the highest standards of medical-grade precision injection molding. It meets the highest standards for biocompatibility, dimensional accuracy, cleanliness, and defect-free performance.

Disposable syringes typically consist of three main plastic components: the barrel, plunger, and needle hub. The injection molding process for each component is crucial.

The following is a detailed injection molding process, which strictly adheres to medical device quality management systems (such as ISO 13485).

Disposable Syringe Injection Molding Process

Phase 1: Material Selection and Preparation

This is the first checkpoint for medical safety, and no compromise is allowed.

Material Selection:

Barrel: Typically transparent polypropylene (PP) or polystyrene (PS) is used. High transparency is required to facilitate fluid visualization, while high rigidity is required to prevent deformation from squeezing.

Plunger: Typically high-density polyethylene (HDPE) or PP is used. Excellent wear resistance and sealing properties are required, and the surface should be threaded to accommodate a rubber piston.

Needle Hub: Typically made of PP or ABS, it requires high strength to securely mount the needle.

Core Requirements: All materials must be USP Class VI or ISO 10993 certified for biocompatibility, demonstrating safety for humans.

Material Handling:

Class 10,000/Class 100,000 Dust-Free Workshop: Raw materials must be stored and handled in a dust-free environment.

Strict Drying: Even in low-humidity environments, they must be rigorously dried in a dehumidifier (e.g., PP at 80-85°C for 2-4 hours) to completely remove moisture and prevent silver streaks or hydrolytic degradation.

Enclosed Conveying: Dried raw materials are automatically conveyed to the injection molding machine hopper via sealed pipes to minimize environmental contamination.

Phase II: Mold Design & Manufacturing

Syringe molds require extremely high precision and surface finishes.

High-Precision Cavity:

The cavity must be mirror-polished (to VDI A0-A1 standards) to ensure the syringe jacket's exceptional transparency and smooth interior, minimizing residual drug residue.

Graduation lines are typically applied to the mold using a texturing process to ensure clarity and durability.

Hot Runner System: This is an absolute standard feature.

A needle-valve hot nozzle ensures beautiful, residue-free gates and precisely controls the filling of each cavity.

Advantages: No runner waste, avoiding the risk of contamination from repeated crushing; and ensuring a stable injection molding cycle.

Venting System:

Precise, deep venting grooves (typically 0.015-0.02mm deep) must be provided to prevent trapped air, which can cause burns (black spots) on the finished product, a fatal flaw in medical products.

Cooling System:

The design must be extremely uniform to ensure dimensional stability and prevent internal stress, which is crucial for the proper fit between the ejector and the jacket.

Stage 3: Injection Molding Process

This process is carried out in a medical-grade cleanroom, with environmental control as the core.

Injection Molding Machine Selection: Electro-hydraulic hybrid or fully electric injection molding machines are used for their high precision, fast response, cleanliness, and freedom from oil and contamination.

Key Process Elements:

High Mold Temperature: Utilizes a higher mold temperature (e.g., 60-80°C for PP) to reduce internal stress, improve melt fluidity, and perfectly replicate the mold's mirror-like surface.

High-Speed, High-Pressure Injection: Rapidly fills the mold cavity with the melt, ensuring consistent molecular chain orientation for optimal mechanical properties and transparency.

Multi-Stage Precision Holding: Utilizes a multi-stage holding profile to precisely control holding pressure and speed, ensuring uniform product density, zero shrinkage or warpage, and micron-level dimensional accuracy.

Stage 4: Post-Processing, Assembly, and Quality Control

This is the ultimate guarantee for product safety and usability, and the process is extremely rigorous.

Post-Processing:

Automated Part Removal: After injection molding, a clean robot automatically removes the product and places it in a dedicated clean packaging box, eliminating direct human contact.

No Post-Trimming: The hot runner valve gate leaves virtually no residue, eliminating the need for secondary processing and preventing particulate generation.

Automated Assembly:

In a cleanroom, the push rod, rubber piston, housing, and needle holder are assembled using automated equipment.

For prefilled syringes, the syringes are filled with the liquid after assembly.

**Rigorous Quality Inspection (100% Inspection + Spot Checks)**:

Automated Optical Inspection (AOI) for Appearance: A high-speed vision inspection system takes a picture of each product to automatically detect and reject defects such as black spots, impurities, bubbles, scratches, and missing material.

Dimensional Inspection: An optical projector or laser measuring instrument is used to perform 100% or frequent spot checks on critical dimensions (such as the housing inner diameter and taper).

Functional Testing:

Sliding Test: The force applied by the push rod within the housing is tested to ensure that it moves smoothly and within specifications.

Leak Testing: Assembled syringes are tested for leaks using negative or positive pressure.

Chemical Performance Testing: Sampling is performed regularly and tested for extractables, oxidizable substances, heavy metals, and other indicators according to pharmacopoeial standards (e.g., USP).

Sterility Assurance: Final products are sterilized using ethylene oxide (EO) or gamma irradiation.

Core Flowchart

Medical-grade pellets → Dust-free storage → Airtight drying → Airtight conveying → Cleanroom → Precision injection molding → Robotic removal → Automated assembly in the cleanroom → 100% machine vision inspection → Functional testing → Sterilization → Packaging → Release

We are a plastic injection mould disposable syringe manufacturer, providing high-quality plastic injection mould disposable syringe manufacturing. As long as you want to customize/develop plastic injection mould disposable syringe products, you can find us. We have professional injection mold design and mature manufacturing technology, providing you with one-stop service, from product design-mold making-product production-product packaging-product transportation, we can help you in every link. As long as you come to us, we will provide you with the ultimate service and satisfy you in terms of product quality, production time, information dialogue, etc.

Plastic Injection Mould making

Plastic molding specifications

Mold design:

Transaction process:

Mold testing:

Product packaging

Factory

We are Custom Plastic Mold factory. Our factory is plastic injection mold maker. we has 17 years of experience in professional custom plastic mold and 10 years of foreign trade experience. We are custom Plastic Mold supplier. We can provide custom Plastic Mold service. Our factory can make the Injection molded plastic parts, and the quality of the products will satisfy you.

We have more than 50 high-end machines and hundreds of engineers and designers. We can provide one-stop service, from product design - mold making - product production - product packaging - transportation. We have a complete production chain. We can meet all your requirements.

Services we provide:

Professional custom mold service, Plastic mold design and manufacturing .plastic product production, product design, mold design, blow mold customization, rotational mold customization, die-casting mold customization. 3D printing services, CNC manufacturing services, product packaging, customized packaging, shipping services.

We always adhere to the principles of quality first and time first. While providing customers with the highest quality products, try to maximize the production efficiency and shorten production time. We are proud to tell every customer that our company has not lost any customer since its establishment.If there is a problem with the product, we will seek a solution actively and take responsibility to the end.

FAQ

Q1: Are you trading company or manufacturer ?

A: We are manufacturers.

Q2. When can I get the quotation?

A: We usually quote within 2 days after we get your inquiry.

If you are very urgent, please call us or tell us in your email so that we can quote for you first.

Q3. How long is the lead-time for mold?

A: It all depends on the products' size and complexity. Normally, the lead time is 25 days.

Q4. I have no 3D drawing, how should I start the new project?

A: You can supply us a molding sample, we will help you finish the 3D drawing design.

Q5. Before shipment, how to make sure the products quality?

A: If you don't come to our factory and also don't have the third party for inspection, we will be as your inspection worker.

We will supply you a video for production process detail include process report, products size structure and surface detail, packing detail and so on.

Q6. What is your payment terms?

A: Mold Payment: 40% deposit by T/T in advance, 30% second mold payment before sending out the first trial samples, 30% mold balance after you agree the final samples.

B:Production Payment: 50% deposit in advance, 50% before sending out the final goods.

Q7: How do you make our business long-term and good relationship?

A:1. We keep good quality and competitive price to ensure our customers benefit for best quality products.

2. We respect every customer as our friend and we sincerely do business and make friends with them, no matter where they come from.