HAHN Automation Group develops integrated overmolding solution
The manufacturing of medical filters poses significant challenges, particularly in integrating delicate membranes into multicomponent housings while maintaining sterility and consistent product quality. Traditional multi-step production increase the risk of contamination, inconsistent membrane positioning, and inefficiencies. This case study shows how an innovative, fully integrated solution addresses these challenges by combining molding, membrane handling, and cutting into a stable and contamination-free process.
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- Fully automated 2C medical filter production via overmolding
- Fast, easy maintenance with quick-change punch & die system
Challenge
The customer manufactured a two-component (top and bottom) medical filter with an integrated membrane – an inherently complex product to manufacture. The conventional process used two separate injection molding machines followed by ultrasonic welding, creating a multi-step workflow with a high risk of contamination to both the membrane and the components. Additionally, membrane cutting and handling were highly complex. Ensuring consistent cutting quality and precise membrane positioning within the filter was a key challenge. The cutting station also required frequent maintenance, causing extended downtime and reduced productivity.
Developing a Solution
To address these challenges, HAHN Automation Group developed an integrated overmolding solution, replacing ultrasonic welding. Both filter components and the overmolding process were combined in a single mold, eliminating intermediate handling steps and significantly reducing the risk of contamination.
A specialized membrane cutting station with torque and pressure control ensured consistently high cutting quality. In parallel, a customized vacuum gripper system enabled precise and reliable membrane positioning.
To further improve efficiency, the cutting station was equipped with a quick-change system for punch and die components. This minimized maintenance time, enabled rapid changeovers, and significantly decreased machine downtime while increasing overall process stability.
