Share
Automating Medical Device Molding: From First Part to Lights-Out Production
Scaling a medical device isn’t just about proving the design works. It’s about proving it can be built repeatably, reliably, and at scale.
In this webinar, Travis Garrison, Automation Manager at Nissha Medical Technologies, and Vijay Kudchadkar, Director of Plastics & Sales Engineering at Nissha Medical Technologies, join Chamfr’s VP of Growth, Steve Maxson, along with Crew Feighery, SVP of Sales & Marketing at MMT, to break down what it actually takes to move from early concept to lights-out production.
The conversation centers on a shift many teams underestimate: automation is not something you implement later. It’s something you design for from the start.
Want to watch the full session? Sign up to access the webinar recording →
Automation Starts at the Concept Stage
One of the clearest takeaways from the session is that automation decisions begin far earlier than most teams expect.
Before tooling, before process validation, and even before final design decisions, there needs to be alignment on how a product will scale.
The Nissha team frames this through their Manufacturing Technology Assessment Process (MTAP), a structured way to evaluate how a product will move from concept to production.
That includes understanding production volumes, acceptable variability, and how the device will be handled, assembled, and inspected as it moves toward commercialization, often requiring early access to the right components and suppliers.
Without that alignment, teams often find themselves redesigning for manufacturability later, when timelines are tighter and costs are higher.
Design for Automation (DFA) Drives Scalability
At the center of that early planning is Design for Automation (DFA).
The discussion highlighted how seemingly small design decisions can determine whether a process can scale efficiently or become constrained by manual workarounds.
Key considerations include:
- Part orientation and handling
- Accessibility of critical features
- Inspection strategy and data capture
These decisions directly impact whether a process can be automated and how repeatable it will be as volumes increase.
As emphasized in the webinar, automation is not added at the end of development. It is enabled through decisions made at the beginning.
From Manual Processes to Lights-Out Production
Scaling production is not a single step. It’s a progression.
Programs typically evolve from manual processes into increasingly automated systems as complexity, volume, and quality requirements grow.
Each stage introduces new constraints across handling, variability, inspection, and system integration. Teams that plan for these transitions early are better positioned to scale without disruption.
As systems mature, metrics like Overall Equipment Effectiveness (OEE) become critical for understanding whether a process is actually delivering the expected throughput, yield, and reliability.
Those that do not often encounter friction when trying to retrofit automation into a process that was not designed for it.
Miniaturization Is Raising the Stakes
As devices become smaller and more complex, the manufacturing challenge increases significantly.
Micro molding and advanced materials are enabling new device capabilities, but they also introduce tighter tolerances, more fragile geometries, and greater sensitivity to variation.
At this scale, even minor inconsistencies can impact performance, yield, and downstream assembly. The margin for error shrinks, and the cost of misalignment increases.
Automation Extends Beyond the Molding Process
Another key theme is that automation doesn’t stop at molding.
Post-processing steps such as bonding, cutting, and inspection are often where variability is introduced. These steps require the same level of intentional design and integration to ensure overall process stability.
When automation is applied across the full workflow, teams can:
- Reduce operator-driven variability
- Improve repeatability and yield
- Achieve more predictable production outcomes
This only works when inspection and feedback are built into the system from the start.
Final Thoughts on Designing for Scale
The difference between a device that works and a device that scales often comes down to decisions made long before production begins.
Designing with automation in mind forces teams to think beyond the prototype. It shifts focus toward repeatability, inspection, and long-term manufacturability.
For MedTech R&D teams, that shift can mean fewer redesigns, faster timelines, and a clearer path to commercialization.
This webinar offers a closer look at how experienced teams approach that process and what it takes to get it right from the start.