Russian

sales01@gdtym.com

2025 Design Contest Winners Announced

+86 188 1411 5468

LOGO

LOGO

Multi-Lumen Silicone Urinary Catheter Production Solution — One Mold Platform, 11 Sizes, 60-Second Cycle

Liquid silicone rubber (LSR) urinary catheters demand tight tolerances and full medical-grade compliance across a wide range of French (Fr) sizes. Our solution uses a shared mold base with interchangeable inserts to cover 11 sizes in both double-lumen and triple-lumen configurations, cutting tooling cost versus a dedicated mold per size...

Cycle Time

60 seconds

Cavities

8 (double-lumen) / 4 (triple-lumen)

Output

~11,520 pcs/day (double-lumen) · ~5,760 pcs/day (triple-lumen), 24h operation

Request a Quote

View Custom Cases

Core Technology Breakdown

130T Vertical LSR Injection Molding Machine (TYM-5058)

Our 130-ton vertical LSR machine is configured with a double lower-mold rotary station and a single fixed upper mold — a layout purpose-built for insert-heavy, multi-cavity medical tubing components. Key specifications include:

- ▸ Clamping force: 130 tons — sufficient rigidity for precision multi-cavity catheter
- ▸ Dual lower mold / double-station design — one lower mold closes and injects while the second opens for demolding and reloading
- ▸ Vertical mold action, well suited to insert placement and gate-free lumen geometry
- ▸ Closed-loop servo metering for consistent shot weight across all cavities
- ▸ Designed for a stable 60-second cycle across both mold configurations

The dual lower-mold rotation is what keeps the 60-second cycle continuous: while one side is under injection and cure, the operator (or automation) is already unloading finished parts and loading inserts on the other side, so the machine is never idle waiting on a single station.

Injection mold for liquid silicone rubber urinary catheter - TYM

Shared Mold Base, Interchangeable Core Inserts

The heart of the cost-saving architecture is the tooling strategy itself, not the machine alone:

- - ▸ One mold base per lumen type — a single base structure supports the double-lumen family, and a separate base supports the triple-lumen family
  - ▸ 11 sets of cavity/core inserts — one insert set per Fr size (6 through 26), swapped into the same base
  - ▸ No full mold rebuild per size — adding or changing a size means machining a new insert set, not a new mold base, ejector system, or runner layout
  - ▸ Faster changeover between sizes, since the base, cooling channels, and ejection system remain fixed
  - ▸ Significantly lower tooling investment across the full 11-size range compared to building a dedicated mold for every size

Result: Full Fr 6–26 coverage in both double- and triple-lumen configurations from just two mold platforms, instead of up to 22 independent mold sets.

Double-Lumen Catheter Mold — 8 Cavities, Cold Runner

The cold-runner mold is the heart of the system. Our design features:

- ▸ 8-cavity cold-runner mold, dual lower-mold rotation
  - ▸ 60-second cycle time per rotation, 8 parts per cycle
  - ▸ Cold-runner design — no sprue/runner waste, no secondary trimming of runner material
  - ▸ Interchangeable insertsts cover all 11 Fr sizes on the same base

Triple-Lumen Catheter Mold — 4 Cavities, Cold Runner

- ▸ 4-cavity cold-runner mold, dual lower-mold rotation
  - ▸ 60-second cycle time per rotation, 4 parts per cycle
  - ▸ Lower cavitation than the double —lumen mold, reflecting the added core complexity of a three-channel lumen geometry
  - ▸ SSame interchangeable-insert platform, covering the same 11 Fr sizes

Robotic Arm — Full Automation

A dedicated robotic pick-and-place system completes the automation loop:

- ▸ Automatically extracts all 24 finished nipples simultaneously after mold opening
  - ▸ Places parts on conveyor or into organized trays for downstream inspection/packaging
  - ▸ Eliminates manual part removal — zero operator exposure to hot molds
  - ▸ Cycle-synchronized operation — no added cycle time for part extraction

With the robotic arm, the entire production cell runs with minimal human intervention, dramatically reducing labor costs and eliminating ergonomic risk.

Production Detail: A single operator can manage 3-4 production cells simultaneously, each producing ~92,000 nipples per day.

Key Benefits at a Glance

Benefit	Detail
Full Size Range from Two Molds	Fr 6–26 (11 sizes) in both double- and triple-lumen designs, built from just two shared mold bases instead of a dedicated mold per size.
Lower Tooling Investment	Adding a new size means machining new core/cavity inserts only — not a new mold base, ejector system, or runner layout.
Consistent 60-Second Cycle	Stable cycle time maintained across both double-lumen (8-cavity) and triple-lumen (4-cavity) configurations.
Dual-Station Continuous Production	The double lower-mold rotation keeps the machine cycling continuously — one side molds while the other is unloaded and reloaded.
Zero-Waste Cold-Runner Molding	No sprues or runners to trim, minimizing material waste on medical-grade LSR.
Fast Changeover Between Sizes	Swapping insert sets on a fixed base is far faster than remounting a full replacement mold.
Scalable to Future Sizes	New Fr sizes can be added to the platform by designing an additional insert set, without new base tooling.

Technical Specifications

Parameter	Specification
Machine Type	130T Vertical LSR Injection Molding Machine (TYM-5058)
Mold Station Configuration	Dual lower mold, single fixed upper mold (double-station rotary)
Double-Lumen Mold	8 cavities, cold-runner
Triple-Lumen Mold	4 cavities, cold-runner
Cycle Time	60 seconds (both configurations)
Size Range Covered	Fr 6,8,10,12,14,16,18,20,22,24,26 (11 sizes)
Tooling Architecture	Shared mold base + interchangeable cavity/core inserts per size
Material	Medical-grade Liquid Silicone Rubber (LSR)

One Supplier. One System. One Guarantee.

Rather than sourcing the machine, the mold platform, and the insert sets from separate vendors, we deliver the entire catheter production system — machine, shared mold base, and the full set of size-specific inserts — from a single source:

No Integration Headaches:

The mold base, insert sets, and machine are engineered together so every Fr size runs on the same validated platform.

Single-Point Responsibility:

We take full accountability for tooling quality, cycle performance, and after-sales support across every size in the range.

Pre-Tested and Validated:

Both the double-lumen and triple-lumen configurations are tested and tuned to the 60-second cycle before the system ships.

Faster Ramp-Up:

Need an additional Fr size later? We design and machine a new insert set for your existing mold base — no new mold platform required.

Proven in Production

Our multi-lumen catheter tooling platform is built for consistent, repeatable results across every Fr size and lumen configuration:

High Yield Rate:

consistently high pass rates across visual and dimensional inspection, maintained across all 11 sizes on the shared mold base.

Low Cavity-to-Cavity Weight Variation:

consistent shot weight across all cavities in both the 8-cavity double-lumen and 4-cavity triple-lumen molds.

Minimal Post-Processing:

Cold-runner molding produces parts with no sprue/runner waste, reducing the need for secondary trimming.

Validated Insert-Change Repeatability:

consistent part geometry maintained across insert changeovers between Fr sizes.

Made for Medical Standards

Our turnkey systems are engineered and manufactured to meet the most stringent international regulatory and quality requirements, ensuring seamless integration into any world-class production facility.

CE-Certified Safety

All electrical components and integrated safety systems are fully CE-certified, guaranteeing safe and reliable operation in global manufacturing environments.

FDA & EU Compliant Processing:

Engineered to meet strict hygiene standards, our system is fully capable of processing food-grade and medical-grade LSR materials compliant with FDA and EU regulations.

ISO 9001 Quality Management:

Our entire workflow—from initial R&D and mold design to manufacturing and final testing—is strictly governed by ISO 9001 quality management protocols.

Comprehensive Global Support:

We provide complete English technical documentation, intuitive English PLC interfaces, and highly responsive global technical support for commissioning and troubleshooting.

Frequently Asked Questions

Projects

Can this mold platform be extended to additional Fr sizes beyond the current 11?

Yes. Because the mold base, cooling layout, and ejector system are shared, adding a new Fr size typically requires only a new cavity/core insert set — not a new mold base.

How long does it take to switch between different Fr sizes on the same machine?

Since only the insert sets are exchanged and the mold base stays mounted, changeover between sizes is significantly faster than swapping a full mold, minimizing production downtime between size runs.

Why does the triple-lumen mold have fewer cavities than the double-lumen mold?

The triple-lumen catheter geometry requires more complex core detail per part, which is reflected in the 4-cavity layout compared to 8 cavities for the double-lumen design — this keeps fill balance and part quality consistent across all cavities.

Is the material and process suitable for medical device applications?

The system is designed to run medical-grade LSR and is built under ISO 9001-governed processes; specific material certifications should be confirmed against your target market's regulatory requirements.

Ready to Transform Your Nipple Production?

Contact us today for a free consultation, process analysis, and quotation.

We can provide production simulations, sample molding, and ROI projections tailored to your specific requirements.