Molds
mold

Molds Manufacturing Capabilities

TAV Medical specializes in manufacturing high precision, multi or single cavity injection molds for complex medical and technical plastic parts. Each TAV Medical mold is uniquely designed and built to provide the reliable and continuous production of accurate and uniform plastic parts. These meet the exacting demands of the medical device industry.

Molds Manufacturing Capabilities

Prototype Production Multi Cavity Insert Over Stack Molds

Mold Design & Manufacturing Process

Mold manufacturing process starts with mold design, which is critical phase in the process. Smart combination between skilled professionals, state of the art technology and close partnership with our customers results in high performance molds and  cost effective parts, molded precisely to customer specifications.

1
MOLD CONCEPT
mold-concept

Our mold manufacturing
process begins with a collaborative effort between our engineers and our customers to define the design intent, material properties, geometry, functionality, and other specifications of the final product. Our team performs 
a feasibility analysis and creates a preliminary mold concept, including ketches, 3D models, and CAD.

2
MOLD DESIGN
mold-design

Based on the mold concept, our team develops a detailed mold design that includes geometric, structural, thermal, and flow simulations, 2D and 3D drawings, tolerances, material specifications, and bill of materials. The design is optimized for manufacturability, cycle time, part quality, and mold durability.

3
MOLD MANUFACTURING
mold-manufacturing

Using CNC machining, EDM, wire cutting, and other advanced manufacturing technologies, we produce the mold core, cavity, and support components with high precision and surface finish. Our manufacturing process is monitored and controlled to ensure the mold's dimensional accuracy, surface quality, and mechanical properties.

4
MOLD TESTING
mold-testing

Our team conducts a series of mold testing procedures to validate the mold's performance, including mold filling simulation, mold flow analysis, mold cooling analysis etc.  We also test the mold with sample parts to evaluate part quality and dimensional accuracy.

5
FACTORY ACCEPTENCE TEST (F.A.T.)
Design of experiments

Our FAT is a formal testing procedure that verifies the mold's compliance with customer specifications and acceptance criteria. The FAT involves a set of standardized tests, including, dimensional inspection, functional testing, and documentation review. The FAT results in a comprehensive report that summarizes the mold's performance and compliance.

6
DESIGN OF EXPERIMENTS (D.O.E.)

Our DOE is a statistical approach that enables
us to optimize the mold's performance by analyzing the influence of various
factors, such as injection pressure, temperature, speed, and packing time. The DOE methodology involves a series of tests and data analysis, resulting in an optimal mold setting that maximizes part quality and mold performance.

7
MOLD VALIDATION
mold-validation

Our mold validation process ensures that the mold meets all the required specifications, including dimensional tolerances, surface finish, part quality, and mechanical properties. We document the validation results and provide a final report for customer approval.

state of the art technology

Technological leadership is the prime objective. We stand right at the forefront when it comes to mold manufacturing technology and operate CNC machining centers, EDM, wire cutting centers etc.

Mold Validation Process

We perform process validation by establishing documented evidence which provides a high degree of assurance that a specified process will consistently produce a product meeting its pre-determined specifications and quality characteristics.

1
PROCESS DESIGN

Commercial manufacturing process defined together with customer based on knowledge gained through development and scale-up.

2
PROCESS QUALIFICATION

The process design is evaluated to determine if the process is capable of reproducible commercial manufacturing.

3
CONTINUED PROCESS VERIFICATION

Continual assurance that the process remains in a state of control – the validated state – during commercial manufacture.

1
Process Design

Commercial manufacturing process defined together with customer based on knowledge gained through development and scale-up.

2
Process Qualification

The process design is evaluated to determine if the process is capable of reproducible commercial manufacturing.

3
Continued Process Verification

Continual assurance that the process remains in a state of control – the validated state – during commercial manufacture.

highlight equipment

• Makino 5 Axis D300 

• Makino 5 Axis V33i 

• Makino 3 Axis V33i

• Makino  V55

• Makino Granite Milling Machine

• Jones and Shipman

• Chevalier Grinding Machine

• Mori Seiki Japan

• Shaublin

highlight equipment

• Makino 5 Axis D300

• Makino 5 Axis V33i

 

• Makino 3 Axis V33i

• Makino V55

• Makino Graphite Milling Machine

• Shaublin

• Mori Seiki Japan

• Jones and Shipman

• Chevalier Grinding Machine

quality control