Aluminium tooling and fast track injection moulded parts for life saving PPE

Fast Track Injection Moulding - running 3,000 parts a day JUST 4 DAYS FROM DESIGN SIGN OFF!

Design for Manufacture critical in moving from 3D printing low volumes to injection moulding and increased production quantities

With the current urgent requirement for PPE by all healthcare sectors, we were approached by Resource 12 regarding the production of single use visors. They had a design that was currently being 3D printed however there was a need to scale up production.

Plunkett Associates was tasked with adapting the design to make it suitable for injection moulding with the aim going forwards to manufacture two aluminium single cavity tools and a full production twin cavity steel tool.PPE Face Shield 

Prototypes were made to check form and fit, and a single cavity tool was trialled to test the material and mould.  

4 days from design sign off and we are running at 3,000 parts a day with a view to producing over 70,000 parts a week once the subsequent tools are operational.  

Parts are shipped to Resource R12 for assembly before being sent out to those most in need and the process of gaining CE accreditation to ensure the visors are of the best possible standard is also underway.

We are delighted to say the project is proving to be a huge success, with moulding well able to support the capacity for high volume production. 

Update 1: 100,000 PPE Visors shipped for NHS and Healthcare Workers!

It’s been just 2 weeks since we first started supplying PPE visors to our client, Resource-12, and we are delighted to report that, to date, we have shipped 100,000 for distribution across the Healthcare sector. Aluminium Tooling

Resource-12 has manufactured the face visors in accordance with BS EN 166:2002 for supply to the NHS/healthcare workers.

Initially our toolroom produced 2 aluminium single cavity tools to get things up and running, followed by a double cavity steel tool which was brought online last week.

With 3 tools in the presses, our mould shop has been busy! Running 24/7 has allowed time for a couple of mods to the tools and means going forwards we have the potential for up to 16,000 parts a day, circa 100,000 a week. 

Those of you who know us, know that we are used to tight timescales and getting things done above and beyond the ‘norm’!

However, to have achieved these quantities in these timescales with the current COVID-19 restrictions has been something of a different challenge! PPE Face Shield

It’s been a huge team effort and we are grateful to everyone who has been involved in making it happen.

Update 2: CE Mark Approval for Face Visor in Record Time!

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