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Silicone micro injection moulding process enabling new products for medical, optical, micro-electronic and other applications Summary An Austrian company developed the first injection moulding process of its kind which is ready for serial production of 2-component silicone micro parts < 10mg. Parts with high precision undercuts and recesses can be produced. Via the 2-component technology, assembly steps (costs/time) are saved. Applications with minimal space/weight constraints and increased functionality are now possible. Original equipment manufacturer (OEM) are sought for technical cooperation & manufacturing agreements. Creation Date Last Update Expiration Date Reference

03 February 2015 21 April 2015 20 April 2016 TOAT20130710001

Details Description Technical silicone products are superior to other materials such as thermoplastics due to high elastic strain (up to 400%) and tear strength and broad temperature range of application (-30°C up to +300°C; without need for additives). In addition, they do not release any harmful/irritating substances (e.g. they are tasteless) when applied. These features in particular enable applications with high requirements concerning legal standards and certifications such as in medical products or baby care articles (soothers). In medical engineering (hearing aid devices, drug carriers etc.) as well as in many other branches (microelectronics, biotechnology) new applications are often challenged by minimum space/weight constraints. Space can be saved by avoiding assembly of parts of different materials. This can be achieved by 2-component injection moulding: instead of 2 parts only 1 part (composed of 2 different materials) is produced with one injection moulding machine. Concerning 2-component silicone injection moulding, technical feasibility so far was limited to a minimal product weight of 10 mg. Thus, requests for products with lower weight could not be fulfilled to date. Due to its profound experience in the field, the Austrian company has now succeeded in developing a production process, which is first of its kind able to manufacture 2-component technical silicone products weighing less than 10 mg. This was made possible by finding and implementing innovative solutions into the process steps tool manufacturing (fabrication of micro-contour, mould alignment), tuning of mixing ratios, demoulding and handling of parts, quality control and tempering. Ref: TOAT20130710001

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The process is ready for serial production and yields silicone micro parts under 10 mg with high precision undercuts and recesses. It comprises a one or two component injection moulding machine, a handling robot for picking and placing of products, a camera system to monitor part geometry, an automated packaging solution and a clean room production facility if necessary. OEM are sought for using the novel process/plant for development (technical cooperation) and/or production (manufacturing agreement) of new products. The Austrian company provides the production plant and development know-how/experience. The partner has to provide the concept and purpose of a new product. Teamwork with the partner commences with the specification process and then extends to material and geometry definition. Product behaviour throughout the entire system is calculated by means of finite element methods. Functional models are produced and the bulk of testing is completed in the Austrian company´s own laboratories. Technical details: • Shot weight: < 10 mg (the lower limits have not yet been explored) • Material: commercially available LSR (liquid silicone rubber); for 2-component parts: LSR & LSR or LSR & Thermoplastics • LSR material: parts with 20-80 shore-A hardness can be realized • All standard colours and mixtures, all additives in powder and liquid form applicable • 1-4 mould cavities possible • Clamping force: 10 kN • 1-component part: max. cavity depth: +/- 10 mm, total 20 mm; max. size: 70x70 mm • 2-component part: max. cavity depth: +/- 6 mm, total 12 mm; max. size: diameter 17 mm • Clean room production possible • Tempering possible Current and potential market applications: Applications where micro-parts with low weight and various functionalities are needed, such as: • Pharma/Medical devices (applications in eyes; drug carrier for implantation in humans; insulin pumps) • Acoustical applications (parts for hearing aid devices) • Optical devices (lenses for LEDs; concentration lenses for solar and photovoltaic industry) • Electronic/Micro-electronic applications (spring elements for laser scanner; diaphragm for loudspeaker) • Biotechnology (sealings for Lab on a chip) • Automotive and aircraft industry (sealings, constructed space optimization) Advantages and Innovations Scaling down of the 2-component silicone injection moulding process to a micro-moulding process required development of completely new solutions for essential process steps (redesign of machines, process and tool-making). The result is an injection moulding process ready for serial production, which is the first of its kind enabling 2-component silicone micro parts weighing less than 10 mg. Many new products or improvements of existing products are thus made possible. Advantages/improvements compared to other product solutions: • Reduction of assembly steps via 2-component technology => saving costs (less material used) and time • Optimal process control and accredited QM-system lead to minimum defects • Saving space and weight for optimized final products • Enabling increased functionality in one part (housing with gasket, integrated pre load or spring force into the part design) • Facilitating applications with the need for assembly of further parts

Ref: TOAT20130710001

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Technical advantages: • Complete solutions for the manufacturing of micro-parts can be offered: planning, product development, tool-making, production, tempering, packaging • Clean room facilities and certifications enable products suitable for medical and pharmaceutical industry. Stage of Development Field tested/evaluated Comments Regarding Stage of Development Ready for serial production; small series of sample parts successfully produced; IPR Status Secret Know-how Profile Origin Private (in-house) research

Keywords Technology 002002017 002002020 006004 006006004 009001009

Microengineering and nanoengineering Moulding, injection moulding, sintering Micro- and Nanotechnology related to Biological sciences Sensors & Wireless products Sensor Technology related to measurements

Market 001006002 005002004 005003003 006005002 008001003

Mobile communications, pagers and cellular radio Drug delivery and other equipment (including kidney dialysis machines) Handicap aids Photovoltaic solar Non-homogeneous injections/extrusions

NACE C.22.1.9 C.22.2.9

Manufacture of other rubber products Manufacture of other plastic products

Network Contact Issuing Partner STEINBEIS INNOVATION GMBH Contact Person Franziska Bergmann Ref: TOAT20130710001

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Phone Number +49 721 935 19 118 Email [email protected]

Client Type and Size of Organisation Behind the Profile Industry >500 Year Established 0 Already Engaged in Trans-National Cooperation Yes Languages Spoken English German Client Country Austria

Partner Sought Type and Role of Partner Sought Type of partner sought: OEM industry Specific area of activity of the partner: Manufacturer of pharma/medical devices (drug carrier, hearing aids), communication devices (acoustical and electronic applications, mobile phones), optical devices (lenses for LEDs, concentration lenses for solar/photovoltaic industry) and products for automotive/aircraft industry (sealings, constructed space optimization); Task to be performed by the partner: Using the novel process for development and/or production of new products; the company provides the production plant and development know-how/experience. The partner has to provide the concept and purpose of a new product. Teamwork with the partner commences with the specification process and then extends to material and geometry definition. Product behaviour throughout the entire system is calculated by means of finite element methods. Functional models are produced and the bulk of testing is completed in the Austrian company´s own laboratories. The co-operation may also start with a rough construction design (part drawing) and product specification provided by the partner. Ref: TOAT20130710001

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Type and Size of Partner Sought >500 MNE,251-500,SME 51-250,>500 Type of Partnership Considered Manufacturing agreement Technical cooperation agreement

Ref: TOAT20130710001

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