Reagent carousel- Urethane Casting Case Study
Project Overview
A world-renowned high-tech company researching chemiluminescence immunoassay analyzer commissioned our company to make 300 sets of reagent carousels.
The internal arrangement of the desired prototype requires many undercuts due to the complex structure. This complexity excludes using the injection moulding or CNC machining method. Chemiluminescence immunoassay analyzers need less than 500 sets a year, as this is the quantity of a reagent carousel. This amount does not meet the requirements for mass production. Even with mass production, the cost would be extremely high due to its complexity.
Urethane Casting is a suitable methodology for products with a production volume between 10-500. INNORATOP fulfilled the customer's requirements without simplifying the original structure, despite the high complexity.
Project Analysis
INNORATOP established a project team after receiving technical consultation from the customer and analyzed the product. A challenging requirement was to produce the required product in the colour white. Due to the particularity of the reagent carousel, this requirement was a non-negotiable factor. We delivered 20 samples as part of this project.
Solution
▷Process selection:
Urethane Casting
▷Surface color
We chose PU8150 to ensure that the natural colour of the product was white, which achieves the same surface effect as injection moulding while avoiding common defects such as shrinkage marks and flow marks caused by injection moulding. The final product delivered a better surface effect than injection moulding.
Project Progress:
Prototyping and testing: 4 days
Constructing mould and testing: 3 days
Production of 20 samples: 6 days
Final test: 1 day
Total: 14 days
After 15 days, INNORATOP delivered the first batch of 20 samples. The high-tech company reordered an additional 280 pieces as they were pleased with the production quality. Since our initial collaboration, we have established long-term cooperation with the client.
