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64-Cavity LSR IV Cannula Connector Solution

The medical liquid silicone rubber (LSR) IV cannula connector market demands exceptional precision, batch-to-batch consistency, and high-volume output under strict quality control. Traditional low-cavitation or manual-trim processes struggle with gate marks, flash, particulate contamination risk, and long cycle times — all of which add cost and compromise medical-grade quality.

Cycle Time

25 seconds

Cavities

64

Output

~221,000 pieces/day (24h operation)

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Core Technology Breakdown

TYM-230 Horizontal LSR Injection Molding Machine

Our TYM-230 horizontal LSR injection molding machine is purpose-built for high-precision, high-cavitation medical-grade liquid silicone processing. Key specifications include:

- ▸ Clamping force: 230 tons — stable and rigid for demanding 64-cavity mold loads
- ▸ LSR metering and mixing system with precision plunger injection unit
- ▸ Closed-loop servo control for consistent shot weight (±0.1%)
- ▸ Designed for 25-second cycle time at full 64-cavity production
- ▸ Integrated temperature control for both mold and injection unit
- ▸ Cleanroom-compatible configuration for medical-grade production environments

The machine delivers the steady clamping force and injection precision required for thin-wall, high-cavitation IV cannula connector molding.

Cold-Runner Precision Injection Control

Feeding all 64 cavities from a single, precisely balanced cold-runner system is critical for medical connector quality:

- - ▸ Balanced flow distribution ensures even fill across all 64 cavities
  - ▸ Eliminates overfill or short-shot defects common in high-cavitation LSR molds
  - ▸ Precise pressure and temperature control throughout the cold-runner channels
  - ▸ Reduces material waste — no sprue degradation, minimal runner scrap

Result: Every sealing ring is uniform in wall thickness, weight, and hardness — critical for consistent pressure-holding performance.

Plastic injection mold for intravenous needle cap - TYM

64-Cavity Cold-Runner Mold

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

- ▸ 4-cavity cold-runner system with 8 needle-valve cold nozzles — zero material waste, no runner recycling needed
  - ▸ 64-cavity cold-runner system — no visible gate marks on the finished connector
  - ▸ Proprietary cooling channel layout ensures uniform temperature across all 64 cavities
  - - ▸ Precision-machined cavity inserts for tight dimensional tolerances on critical sealing surfaces

The cold-runner molding process produces IV cannula connectors with clean, flash-free surfaces — ready for downstream assembly or sterilization without secondary deflashing operations.

Robotic Arm — Full Automation

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

- ▸ Automatically extracts all 64 finished parts after mold opening
  - ▸ Places parts into organized trays for downstream inspection, cleanroom packaging, or assembly
  - ▸ Eliminates manual part handling — reduces contamination risk and operator contact
  - ▸ Cycle-synchronized operation — no added cycle time for part extraction

With the robotic arm, the entire production cell runs with minimal human intervention, supporting the contamination-controlled handling that medical-grade LSR parts require while reducing labor costs.

Production Detail: A single operator can manage multiple production cells simultaneously, each producing ~221,000 IV cannula connectors per day.

Key Benefits at a Glance

Benefit	Detail
25-Second Cycle	Industry-leading cycle time for 64-cavity LSR connector production — 64 pieces every 25 seconds.
Zero-Waste Molding	Cold-runner system with balanced flow = minimal scrap, near 100% material utilization.
No Water Gate, No Flash	Precision cold-runner control produces clean, flash-free parts ready for medical assembly.
Fully Automated	Robotic extraction + tray/conveyor integration = true lights-out operation with minimal manual contact.
Consistent Quality	High-cavity mold design ensures every connector is identical within tight tolerances.
Fast Time-to-Market	Complete turnkey solution — machine, mold, automation, and process parameters tuned and validated before shipment.
Lower Labor Cost	Automation eliminates manual trimming, inspection sorting, and repetitive handling labor.

Pressure cooker silicone o ring mold - TYM

Technical Specifications

Parameter	Specification
Machine Type	TYM-230 Horizontal LSR Injection Molding Machine
Injection System	Servo-driven plunger, closed-loop control
Shot Weight Precision	±0.1%
Mold Cavities	64 cavities, cold-runner design
Runner Type	Cold runner
Cycle Time	25 seconds (64 pieces per cycle)
Daily Output (24h)	~221,000 pieces
Automation	Machine sweeping
Material	Medical-grade Liquid Silicone Rubber (LSR)
Application	Medical IV cannula connector / injection port seal

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 machine and mold are designed together to ensure optimal performance and seamless compatibility.

Single-Point Responsibility:

We take full accountability for the overall quality, performance, and after-sales service of the entire system.

Pre-Tested and Validated:

The complete system is rigorously tested, tuned, and validated as a single functioning unit before delivery.

Faster Ramp-Up:

With process parameters already configured, your team can start mass production within days of installation.

Proven in Production

Our 64-cavity LSR IV cannula connector solution is already running in production environments, delivering:

High Yield Rate:

Consistently achieves industry-leading pass rates during both visual and dimensional inspections.

Ultra-Low Weight Variation:

Maintains tight cavity-to-cavity weight consistency, ensuring identical product geometry across all 64 cavities.

Minimal Post-Processing Requirement:

Produces flash-free parts with minimized gate marks, reducing the need for deflashing or gate trimming.

Long-Term Process Stability:

Sprueless cold-runner design maintains stable output without process drift over extended production runs.

Made for Global Standards

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 system handle different connector sizes and designs?

Yes. The mold design can be customized for different IV cannula connector shapes, sizes, and hardness specifications. The machine's injection parameters are fully programmable for quick changeovers between products. We recommend dedicated molds for each product for optimal cycle time and quality.

What is the typical ROI period?

Most customers achieve full ROI within 8–12 months, depending on production volume and local labor costs. The combination of 25-second cycle, 64-cavity output, and near-zero labor requirement delivers dramatic per-piece cost reduction compared to conventional low-cavitation LSR injection or compression molding.

What training and support do you provide?

We provide comprehensive on-site training for operators and maintenance technicians, complete documentation (machine manual, mold maintenance guide, process parameters), and remote technical support. Our engineers are available for on-site commissioning and troubleshooting worldwide.

Can existing molds be adapted to this machine?

Our TYM-230 machine uses standard mounting patterns and ejector configurations. Existing molds can often be adapted with minor modifications. We provide a free compatibility assessment for any existing mold you wish to run on our system.

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.