Micro Assembly
From initial concept, we design, manufacture and assemble dust-speck sized micro parts and features to be able to be manufactured in both small and large volumes.
We work in a variety of fields with expertise in the medical and pharmaceutical industries.
Recent Parts
Micro Molding – Micro Filter
Polypropylene insert molded filter used in air quality inhalation reader for mimicry industry. Full automation turnkey system running multiple millions annually.
Micro Assembly – Prostate Seed Marker
PEEK prostate seed 2mm (0.080″) long, prefilled and automated.
Micro Needle Assembly closeup
Insulin Pump Disposable, hole in center = 0.005″
Micro Needle Assembly
Insulin Pump Disposable
Recent Projects
Single Dose Powder Inhaler
The DoseOne™ Single Dose Powder Inhaler is human factor-ready and API tested for Actives in several molecule sizes. Patented in several embodiments, our technology enables two different powder drugs to be simultaneously released with the same inhalation. With five total parts, it is currently designed for scalability and economic validation and manufacturing. Micro Engineering… Read More »
More on Micro Assembly
The preparation required for micro components at the design stage carries through all the way to automated assembly. Because the tolerances are critical and diminishing to microns and sub-microns, the stack-up tolerances of the micro components and their design criteria are scrutinized and their method of manufacturing are also considered for long-term production. The mechanics of micro assembly and the testing, inspection, application knowledge are required for fully functioning specks of dust working collaboratively and repeatedly. Handling these components is a challenge requiring high speed automation capable of handling dust speck sized parts, in-line metrology and vision systems to insure form, fit, and function, and positional accuracy to sub-micron tolerances. These joining/assembly methods include:
- AVOIDANCE OF HANDLING- Combining geometry into the least number of parts in a micro assembly
- TWO-SHOT MICRO MOLDING/OVER-MOLDING- Two-shot molding (2 injection barrels of two different materials) injecting into a mold at two different locations or in the same location with a rotating mold
- LASER WELDING- Careful control of laser energy and power densities can be used to selectively clean and strip materials such as wires quickly and non-destructively.
- ULTRASONIC WELDING-Very tiny (70-100 um) weld beads are possible with custom low energy boosters and ultrasonic horns.
- SOLVENT BONDING-Appropriate solvents must be used that are compatible with the materials being solvent bonded, especially if the assembly is to be used as an implantable.
- STAKING- Crimping or staking is a very common practice to generate good seals for preventing costly fluids from escaping the micro vessel.