- Material: LCP (Liquid Crystal Polymer)
- Overmold wall thickness: 0.004" (0.1016 mm)
- Final part outer diameter: 0.047" (1.1938 mm)
- Process: Overmolding
- Inspection: In-house CT scanning
- Application: Cardiac electrophysiology
The Challenge: Overmolding LCP at a 0.004" wall around a small, irregular metal electrode introduces two compounding problems:
- filling a thin section before the LCP freezes
- holding electrode position precisely enough that the overmold wall remains uniform around the substrate.
The Solution: MTD's tool was designed with built-in compensation for slight variability in the supplied electrodes, so the overmold wall remained uniform across an inherently variable substrate. Each electrode was hand-loaded into the tool under microscope, using vacuum pens, by an operator trained for this geometry — preserving electrode orientation through the load and shot.