High-Sealing & High-Pressure Medical-Grade Mold Manufacturing

Project Overview
We delivered an end-to-end tooling solution—from DFM and Moldflow analysis to precision fabrication and trial production—for an interventional balloon inflation device. The mold suite produces key components: a high-transparency pressure barrel, a quick-release locking handle, and a three-way stopcock. The design successfully resolves injection shrinkage and residual stress in high L/D barrels, while enabling reliable demolding of self-locking threads.

Technical Highlights
Medical Optical Barrel: Crafted from hardened S136 steel with SPI A1 mirror polishing (Ra <= 0.02 um) and conformal cooling channels, achieving exceptional optical clarity, low residual stress, and minimal air entrapment.
Precision Locking Mechanism: Critical insert tolerances were maintained within ±0.003 mm via slow-wire WEDM and EDM. Optimized split-thread tooling guarantees smooth engagement and prevents thread stripping under high hydraulic load.
High-Pressure Burst Resistance: Moldflow-guided gate placement and stress distribution ensure the assembled device consistently passes > 30 ATM burst pressure and long-term sealing tests.

Value Delivered
Through rigorous engineering validation and efficient mold tuning, we seamlessly supported the customer through medical-grade quality verification and trial production, significantly accelerating time-to-market.

   Note: Image displays the final balloon inflation device featuring core components molded with our high-pressure optical-grade tooling.