Case

A medical device client specializing in surgical instruments required a reliable supplier for their disposable stapler components, which demanded high-precision dual-shot injection molding. The product’s ergonomic handle combines a rigid structural housing with a soft, skin-friendly grip, both of which are critical for safe and comfortable use during procedures. Previously, the client faced significant challenges with their supplier. Attempts to mold the hard and soft components separately and then assemble them led to inconsistent fit, weak bond strength, and hygiene risks from secondary handling. The multi-step process also resulted in long lead times, high labor costs, and yield rates too low to meet regulatory and volume requirements. Delays in production were slowing their product launch and threatening their position in a competitive market. After a thorough evaluation, the client selected us for our specialized expertise in medical-grade two-shot molding. We designed a custom rotating mold that first injects the rigid white housing, then indexes to a second cavity to overmold the blue soft-grip material in a single, automated cycle. This eliminated the need for secondary assembly entirely. We also implemented strict process controls to ensure material compatibility, bond integrity, and full traceability for every batch. As a result, we delivered fully integrated, contamination-free components that met the client’s exact specifications. The one-shot process improved yield, reduced lead times, and cut production costs. With stable, high-volume production now in place, the client successfully launched their new device on schedule, confident in its quality, safety, and performance.