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Surgical Applications
We've found that surgical instruments are truly a perfect fit for Matrix. These devices often require strict tolerances, complex actions, critical dimensions, demanding materials, and advanced inspection reports - all of which play to our strengths. One such example was an anastomosis system designed to simplify on- or off-pump cardiac surgery.
Project Background
This proprietary device automates the connections, or anastomoses, of blood vessels during coronary artery bypass graft (CABG) surgery. These devices are designed to replace hand-sewn anastomoses, which are time consuming and difficult to perform.
Matrix has been directly involved with the development of this device since its inception in 2001. The cartridges of these units are very complex and contain many micro plastic components. 13 to 15 micro parts must align perfectly with each other as well as surrounding metal components to function reliably.
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Challenges
In order to hold tolerances of ±.0005" on these interconnected plastic parts, the tools often had to be played steel-safe and tweaked in by hand during sampling. Having integrated molding and tooling departments made this possible without compromising the delivery date.
Additionally, all plastic components on the device head are molded in PEEK, a high strength medical grade resin suitable for contact with human tissue. Due to its physical properties, PEEK has a high viscosity, requires very high melt temperatures, and can make filling micro features a difficult task. Matrix has many years of experience molding challenging resins such as PEEK.
The inspection requirements are equally demanding, but technological improvements such as our cross-sectional scanner and video microscope have nearly automated the process of thorough part analysis.
Results
In searching for the right vendor, our customer chose Matrix because we had proven ourselves capable of providing the complicated tooling, the finished product quality and we were responsive to the demands they faced in getting these products developed, tested and approved for use.
During the course of this job, R&D engineer Michael Schaller had this to say about Matrix:
"Matrix's technical abilities are unsurpassed both in tooling and molding, but I consider one of their biggest assets to be their availability. From the president to the tool maker, it's always easy to get someone on the phone and spend considerable time talking through issues."