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Design for Manufacturability
Case Study

Ensuring the Manufacturability of a Complex Functional Design

A leading diagnostics company asked us to produce a container system (cassette) for use in a new diagnostic analyzer for tumor identification and classification.

The system consisted of a series of containers with different capacities that were to be clipped into a holder that would also serve as a size adapter, so that the containers could be inserted into the analyzer with a precise fit, even though the smallest container was only one-third the size of the largest. The containers had to have a complex geometry with an asymmetrical neck opening and had to be designed to empty completely without residual volume.

This combination of requirements made the design of the container system particularly challenging. The task was to realize these functional features while optimizing the design for efficient large-scale production with consistently high quality.

Container system for diagnostics

Smart Design Fine-Tuned for Optimum Results

We approached the task by selecting the manufacturing technology that guaranteed the highest product quality for each of the individual components.

This resulted in a combination of three technologies for manufacturing the parts. The adapter was injection molded, while one component was injection blow molded and two other components were extrusion blow molded. The mold was designed to keep the wall thicknesses of the containers constant within the tight specified tolerances. The system was also smartly designed so that incorrect assembly was impossible.

Unique Range of Technologies for Processing Thermoplastic Materials in the Cleanroom

Our core technologies at our certified GMP sites in Neuhaus and Brensbach are (multilayer) extrusion blow molding, injection blow molding and injection molding. All processes, as well as assembly and packaging take place in clean rooms of GMP classes C+D.

This makes us unique in the market, especially in light of our deep understanding of automation and tooling and our many years of experience in developing and manufacturing complex packaging solutions for the pharmaceutical and diagnostics industries.

Röchling Medical offers technologies for processing thermoplastic materials in the clean room

Supplier of Choice for Multicomponent Products

Because of the range of manufacturing processes offered at Röchling Medical, we were able to offer the most suitable process and combination for each part of this multi-component product.

Our deep understanding of production processes and mold making, as well as many years of practical experience in designing and manufacturing a wide variety of bottle geometries and output quantities, ensure a high level of consulting expertise.

Röchling Medical Competences

Our Expertise, Your Benefit

Our customers benefit from our extensive expertise in plastics and metal processing, but also from our many years of experience in medical technology and pharma. As your solution partner, we are familiar with both the regulatory and practical requirements of creating components and products for the healthcare sector tailored to your needs. We meet the highest quality and hygiene standards and operate in strict compliance with relevant regulations, such as the Medical Device Regulation (MDR).

Contact Us

For more information about customized design solutions, please contact our team.

We look forward to hearing from you.

Markus Fritzmann Röchling Medical

Markus Fritzmann
Head of Regional Sales

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