NextGen Medical Solution

Efficient. Validatable. Future-proof

The innovative "NextGen Medical Solution" production cell has set a new standard in production for the medical sector. Working closely with a renowned OEM and our partners Hack and HB-Therm, we developed a pioneering solution that combines efficiency, quality, and digitalization. From the very beginning, the focus was on clear objectives: a comprehensive assessment of the total cost of ownership (TCO), a significantly shorter time to production, and extremely simple and intuitive usability.

Sustainable production

The production of caps for injector pens made from medical-grade PP results in a significantly reduced product carbon footprint thanks to innovative technology and the optimized selection of materials.

Rapid validation

Intelligent assistance systems and a holistic approach ensure particularly fast and efficient qualification and validation.

Compact system design

The well-thought-out overall design of the production cell reduces the space required by up to 25% compared to standard automated solutions.

Challenge

Developing a production cell for the medical technology industry placed the highest demands on speed, precision, and process reliability. In addition to rapid production readiness, it was particularly important to ensure reproducibility, complete traceability, and reliable adherence to all process parameters. At the same time, the goal was to ensure consistent and transparent data documentation and to significantly accelerate qualification and validation processes. The challenge was also to optimally integrate all components—from the machine to peripheral equipment—design them to be compact, and enable smart interlinking via a central control system. The goal was to develop a customized, future-proof solution that enables maximum transparency, efficiency, and process stability in medical production.

Solution

This holistic approach enables a fully integrated production cell characterized by high efficiency, quality, and transparency. The seamless integration of all peripheral devices results in a stable, continuous production process. Intelligent assistance systems continuously monitor and optimize processes, increase system availability, and ensure consistently high component quality. The compact automation concept also ensures maximum productivity in a minimal amount of space, even under clean-room conditions. The solution is complemented by intelligent energy and process optimizations that reduce resource consumption and increase productivity. Thanks to comprehensive interlinking, fast setup processes, and a preventive maintenance and spare parts strategy, cost-effective high-volume production with a low total cost of ownership is made possible.

The production cell is fully prepared for parametric approval and enables fast, reliable validation. The result: globally scalable production of the highest quality—while minimizing time to market.

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“The joint development of new technologies is focused and efficient since the expertise of each partner is taken into account from the very beginning. From day one, this collaboration has combined all the strengths of each partner into a single, integrated, and user-friendly solution.”

Christopher Dickreiter, Senior Molding Engineer, Industrialization, Sanofi S.A

Outlook

Today, the production cell is already fully integrated and digitally interlinked. Consistent use of all assistance and pilot functions provides optimal support for the entire process, from commissioning to series production. Centralized monitoring of all components ensures maximum transparency and control throughout the entire production process. This solution already offers a glimpse into the future of medical device manufacturing: integrated, efficient, fully automated, and maintained proactively.

The project partners

ARBURG

ARBURG's all-electric production cell in "Medical Design" features highlights such as water-cooled direct drives, a fully integrated 6-axis robot, and digitally integrated peripheral equipment. The GESTICA control system, with its intelligent and AI-driven functions, meets all the requirements for the injection molding of future medical devices

Hack

High-precision 8-cavity injection molding tool with sliders and a full hot-runner valve gate system—enhanced with integrated sensor technology.

Hack digital solutions

Innovative mold monitoring system with "moldlife sense" sensor technology, fully integrated into the injection molding machine.

HB-Therm

With the Thermo-6 temperature control unit, HB-Therm combines outstanding energy efficiency with reliable temperature and flow management—seamlessly integrated into the machine.