2008 Award Winner

HX2 Temperature Management System

Profile wins again at the 18th Annual Thermoforming Parts Competition in Minneapolis, Minnesota

Terumo Cardiovascular Systems (TCVS) offers the HX2 Temperature Management System for precise control of a patient's body temperature during heart surgery.  The initial design and subsequent production included covers that were rotationally molded.  However TCVS presented us with the opportunity to solve some problems they were having with their rotationally molded covers:

1. Roto molded covers could not meet the product's dimensional requirements on a consistent basis.

2. Roto molded covers were heavy due to the wall thickness required to meet UL standards.

3. Roto molded covers exhibited inconsistent color run to run.

The Solution:

1. Use pressure-formed covers to duplicate the exterior surfaces but with a much higher degree of consistency that allow for a precise line to line fit up.

2. Robotically machine backside mounting blocks for precise attachment points to the machine space frame.

3. Pressure form parts with Kydex T material.  Although denser than LLDPE used for rotational molding the Kydex T can meet the UL94 V-0 at .028".  This allows for a thinner wall and results in a 50% weight reduction.

4. Pre-color the plastic sheet and then use proper heating techniques to minimize the color shift.

Re-tooling the covers for pressure-forming eliminated the problems TCVS was having with the roto-molded versions.

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