Direct Compression Moulding (DCM)

THE ORTHOPLASTICS INSERT MOULDING PROCESS

High standards and expectations at Orthoplastics demand that all customers are provided with premium quality products. Therefore, Orthoplastics use a process called Direct Compression Moulding to sinter polymers. This method of moulding polymers results in an outstanding high gloss finish, thereby resulting in a near net shape, or net shape component.

Extra attention has been paid to advancing this method, allowing Orthoplastics to use the optimum approaches towards producing the best possible UHMWPE components for their clients. Orthoplastics successfully developed an ‘insert moulding’ process which enables them to mould UHMWPE onto or into another titanium, steel or ceramic part.

DIRECT COMPRESSION MOULDING SERVICES

Orthoplastics’ Direct Compression Moulding services are at the cutting edge of new product development. Although the technology has been in existence since the 1990’s, the new generation of technologies which have been invested in, particularly the 3D printer, allows printed metals and other porous metals technologies to be created. This has provided Orthoplastics with the ability and opportunity to over-mould plastics, and create a mono-block solution for customers and device manufacturers.

ALLOWS MEDICAL GRADE MOULDING OF INDIVIDUAL COMPONENTS

Although Direct Compression Moulding is a premium method of sintering the polymer - compared to traditional consolidation methods - it has the capability to produce products which cannot currently be produced, pushing the design envelope for medical grade orthopaedic components.

By focusing on innovation, this method of manufacture has produced unique over moulding capabilities. Producing Mono block components that have a high gloss moulded surface. These design and aesthetically pleasing products provide an alternative market solution to any OEM’s portfolio. Each component is individually moulded, allowing the finite controlling of all aspects of pressure, temperature and time, during critical consolidation. The finished product’s high gloss surface finish and tolerances are superior when compared to a machined UHMWPE component.

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