Moulded parts made to measure
Midas is producing the interlocking plastic covers for the NanoSight NS500
Polyurethane moulding specialist Midas Pattern Company is producing sets of covers for Prior Scientific, a supplier of customised OEM products to the microscopy and metrology market.
The stylish covers are used on a new instrument for nanoparticle analysis and characterisation applications.
Around 20 years ago, in a concerted move to diversify, Cambridge-based Prior Scientific looked to build on its core business with a venture into OEM projects. Today, this accounts for 30% of revenue at this £12m turnover UK-headquartered company, which now has additional facilities in the US, Germany and Japan.
Prior was approached in early 2010 by NanoSight, a Wiltshire-based company specialising in an innovative technology called Nanoparticle Tracking Analysis (NTA). NanoSight wanted to design and manufacture an NTA instrument which uses a laser and novel optical configuration to analyse through advanced software the presence, size distribution, concentration and fluorescence of all types of nanoparticles from 10nm to 1000nm.
Importantly, a computer-controlled motorised optical stage was specified and it was this functionality that originally made NanoSight turn to Prior Scientific, a company with extensive experience in motorised XY microscope stages. However, as it turned out, this was just the beginning.
“After an initial consultation it soon became apparent to both parties that Prior Scientific was best placed to take on the design of the mechanical and control elements of the complete instrument, not just the motorised stage,” explains Mechanical Design Engineer, Jim Norwood. “OEM projects are a big part of our core business today and we knew we could offer NanoSight a high quality, cost effective and expedient solution.”
An industrial designer was invited to look at the skeleton of the 400mm high unit with the intention of designing a set of covers. Because of the laser, the covers had to be interlocking.
“A number of concepts were presented to NanoSight – and they ultimately opted for a three-cover approach: a top cover, door and base unit cover, with the top cover and door interlocked to the base.
Prior Scientific knew that an expert manufacturer would be required to produce the covers. The relatively low volumes could not be cost effectively manufactured by conventional mould shops, and high accuracy and tight tolerances were required to achieve the interlocking functionality and the removal of the top cover for loading and service of the laser module. Furthermore, a quick response was needed – the first batch had to be ready for product launch at an exhibition in April 2010.
“Timing was a big issue, an exhibition in the US had been identified as a suitable launch platform,” says Mr Norwood. “Fortunately we had worked with Midas Pattern Company before and knew their capability.
We spoke with them about the project and they confirmed they could respond within the required timeframe.”
Having reviewed the design of the covers, Midas was able to offer advice on certain criteria such as wall thickness and mould optimisation. This information was duly adopted in order to rationalise ease of manufacture and product cost.
Advice was also given on material, with UL96 VO rated flame-retardant polyurethane being the selected option. Colour was another point for debate – Midas supplies the top cover in an attractive painted grey finish, with the door and base unit cover supplied in blue.
“Midas delivered on their promises with the first batch arriving in March 2010 in time for the exhibition a month later,” says Mr Norwood. “Midas’ process suits the quality and volume requirements for the NanoSight NS500 perfectly, and with their help another OEM project has been concluded successfully.”
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