Volumetric Dispensing Brings New Levels of Repeatability to Medical Device Manufacturing

As medical device companies look to reduce rework and improve accuracy, repeatability has become an important requirement when purchasing manufacturing equipment.

Ensuring you are receiving the same results each time when dispensing fluid onto a part will help get parts inspected and approved in a more timely manner.

Nordson EFD’s 797PCP-2K progressive cavity pump for volumetric dispensing, along with EFD’s PROPlus automated dispensing system helped a medical device manufacturer achieve better accuracy and repeatability, as well as save money and produce less waste.

EFD’s 7197PCP-DIN-NX controller was also used to support Smart Factory integration and bring efficiency to the dispensing process by allowing operators to control all dispensing parameters from a central PLC.

Fluids Used

2-part epoxy

Application Requirements

Ability to inject fluid into a small diameter hole on the plunger stop component

Apply consistent amount of fluid at a weight of less than 0.2 mL

Repeatable dispensing with accuracy of ± 1%

Remote dispensing control through a PLC

Previous Process

Before purchasing the 797PCP-2K progressive cavity pump, the epoxy was applied in two places on the plunger stop component using a two-component fluid dispensing machine. The machine was fed through a drum and into a syringe, which would dispense onto the part.

Issues with Previous Process

The two-component system was previously purchased for another project, so this machine was in-house. This was convenient for the team because they didn’t need to find new technology, but the engineers soon found out that this system wasn’t going to work for their specific needs.

Drawing the fluid from the drum left too much time for the material to sit, and the fluid would quickly cure before the material dispensed. This left a large amount of material unusable, which led to costly waste. The team ended up going back to manual hand dispensing, which slowed their process tremendously.

Solution

797PCP-2K progressive cavity pumps

7197PCP-DIN-NX controllers

Optimum 20 ga tapered dispensing tips

Series 190 disposable plastic spiral bayonet mixers

PROPlus Series automated dispensing system

Results

When the team reached out to EFD for help, they made it clear that achieving repeatability was their most important goal. Based on this need and their 2-part fluid, the 797PCP-2K progressive cavity pump was recommended. This industry-leading volumetric dispensing system is highly repeatable, with fluid deposit accuracy of ± 1%, which met their accuracy requirements exactly. The programmable suck-back feature provided more accurate dispensing without dripping or drooling, so fluid will never be wasted like in their previous process.

797PCP-2K Progressive Cavity Pump

EFD’s 7197PCP-DIN-NX controller was introduced to the team when they mentioned they were looking for a way to control their dispensing through a PLC. This network capable controller provides precise control of dispensing parameters for automated dispensing applications. It allows direct communication with a PLC or other manufacturing plant controllers using NX protocol via Ethernet for Smart Factory integration.

7197PCP-DIN Controller

The PROPlus automated dispensing system was something that the team had previously purchased and already had in-house. This worked out perfectly because the PROPlus delivers the best-in-class dispensing performance and process control. The level of precision required for this plunger stop application could only be achieved on a highly repeatable, closed-loop dispensing system equipped with a CCD camera and a tip detect device, all of which the PROPlus offers.

PRO Series robot with the xQR41 valve dispensing UV onto a PCB.

With the 20 ga SmoothFlow tapered tip attached to a Series 190 spiral bayonet mixer, and the 797PCP-2K on a PROPlus robot, the team was able to achieve the highest repeatability and most precise fluid deposits for their application.

After implementing all the Nordson EFD fluid dispensing equipment that was recommended, the team realized they had found the dispensing process they had been looking for. The 797PCP-2K dispensed the exact amount of fluid each time to reduce waste and cost. The fluid was no longer sitting long enough to start curing, like in the previous process, and the deposits were the correct weight and size that was needed. The small gauge dispensing tip allowed the deposits to be properly measured and placed neatly on the plunger stop component.

This new method of dispensing has helped the team tremendously and they are planning to purchase more EFD equipment in the future.

Nordson EFD is here to help you meet all your medical application requirements, whether it be for plunger stops or other life-saving devices.

If you have any questions or would like to speak with an experienced application specialist, don’t hesitate to email us at info@nordsonefd.com.