Energy Management Case Studies

POLYFORM® Molded Foam Inserts for Medical Equipment

Description of the Request:

The manufacturer of medical equipment materials, specifically a respiratory medical device, had a three-element design requirement that could only be met with a single molded part. The manufacturer's requests were:

1) Reduce the number of pieces that were being assembled into the device.

2) Overall product noise reduction.

3) Reduce total manufactured costs.

Medical Equipment Material Solution:

Working with the engineering department of the manufacturer, Polymer Technologies, Inc. determined that all three design requests could be addressed through the creation and installation of a single, three-dimensional molded foam part.

Several design iterations were prototyped and tested before the final molded configuration was approved by the customer. The final product accomplished all manufacturer requests:

  • Reduced 37 different assembly items to a single molded foam part.
    The design of the POLYFORM® insert allowed for the elimination of various isolators, screws, nuts, washers, fixtures, clamps, molded plastic pieces and several die-cut foam parts.
  • Overall product noise reduction by 4 dBA.
    The POLYFORM® molded urethane foam part acted as a shock isolation platform for the blower motor assembly as well as an absorber for the airborne sound energy generated by the blower motor, resulting in the noise reduction.
  • Lowered the manufactured cost of the medical device by 12%.
    Elimination of the above mentioned assembly pieces helped to reduce manufacturing assembly time by over 40%. Ancillary benefits included reduced inventory, fewer part numbers and supplier consolidation.

(Specifications subject to change without notice. Check with factory for latest revisions.) The Federal Trade Commission considers no existing test methods or standards regarding flammability as accurate indicators of the performance of cellular plastic materials under actual fire conditions. Results of existing test methods, such as UL-94, MVSS-302, SAE J-369, and FAR 25.853 are intended only as measurements of the performance of such materials under specific controlled test conditions. Any flammability ratings shown are not intended to reflect hazards presented by these materials under actual fire conditions.

The information contained herein is based on laboratory test data developed for PTI and is believed to be reliable, but its accuracy or completeness is not guaranteed. The buyer must test any product to determine the suitability for h is specific application before use. PTI DISCLAIMS ANY RESPONSIBILITY FOR: 1) WARRANTIES OF FITNESS AND PURPOSE, 2) VERBAL RECOMMENDATIONS, 3) CONSEQUENTIAL DAMAGES FROM USE AND 4) VIOLATION OF ANY PATENTS OF TRADEMARKS HELD BY OTHERS.

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