Having once shifted from molding cellphone housing to functional decorative automotive parts, Helmbrechts, Germany-based KH Kunststoff Helmbrechts AG has more recently reduced its auto industry dependency by becoming active in the development and production of medical devices.
This is well exemplified by the market introduction of the new niia essential patch-based basal-bolus insulin pump, developed by Biel/Bienne, Switzerland-based PharmaSens AG together with Leigh, Scotland-based Shore Group.
The 45-by-18-millimeter device measures glucose levels and delivers insulin via a single patch. PharmaSens applied for U.S. Food and Drug Administration approval in December 2023. Two further versions are due to follow niia essential, which combines insulin pen ease with advantages of a sophisticated insulin pump but "without all the whistles and bells," according to PharmaSens.
KH uses two-component hard/soft molding for the polycarbonate rigid plastic housing and three interconnected soft black TPE operating function areas. A 250-microns-thick white relatively opaque in-mold labeling polycarbonate foil is selectively screen printed with six layers. It has a translucent tint along with an opaque lettering. A scratch- and chemical-resistant lacquer top coating completes the foil preparation.
This is all prior to shaping, stamping and insertion of the foil into a mold for back molding, taking particular care not to distort the symbols, especially the central illuminated ring area.
The final result is a "black panel" effect commonly used in automotive interiors, which ensures functions only appear when touch-activated. But it is slightly toned down, enabling some "intuitive" visibility rather than complete disappearance.
Use of relatively opaque PC foil ensures adequate visibility of the white symbols and illumination without undesired stray lights. KH finally assembles all 13 components of the niija essential, a challenging task due to limited space.
Head of Sales Christian Pohlschmidt said the molding is so precise that it is impossible to feel any difference when stroking the exterior PC/TPE interface. He said KH molds the parts in a clean room mold environment, with the moldings passing through to clean room assembly and packaging.