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Joining of Miniature to Micro Medical Parts Using Insert Micro Molding

10/01/05:  Micro Molding parts are defined as fractions of a plastic pellet, weight fractions of a gram, have tolerances with micron feature sizes and/or tolerances.  Assembling micro devices onto other micro sized components or larger components requires high speed automation and/or tedious microscope assembly operations.  This paper explores the method of insert micro molding and micro over molding and some challenges overcome to create minimally invasive surgical instruments and micro electronic devices.

Combining micro components in either metal to plastic or plastic to plastic can be challenging due to the size constraints of the components.  Part handling, part degating, and joining strength methods of insert micro molded components will be explored and compared to other assembly alternatives.