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An assay instrument ships with subassemblies worth more than the rest of the machine combined: optical benches, pump heads, machined housings with medical-grade finishes. One fleck of packaging foam stuck to an optical surface can cost a week of rework. This is the reason medical device plants specify EPP instead of shredded paper, loose fill or open-cell foam.
Closed cells do not shed. Molded EPP presents a fused bead surface with no loose fibers, so nothing rubs off onto finished components during loading, storage or the ride to the next plant. Parts can go from the insert straight into final assembly without a wipe-down step.
Shapes that irregular parts actually rest in. Surgical handpieces, curved sensor housings and cast housings with ports all get their own cavity, formed in the mold rather than carved. Deep sections, side recesses and fragile probes are captured, not balanced on flat foam.
Spec list:
MD 4540 insert: 450 x 400 x 90 mm, two-part clamshell, 60 g/L EPP.
MD 6045 insert: 600 x 450 x 100 mm, single tray, 12 component cavities.
MD 8060 insert: 800 x 600 x 120 mm, lid and base set for full assemblies.
Density range: 45 to 80 g/L, selected per part mass and drop height.
Surface resistance: dissipative grade available for electrostatic parts.
Compatibility: EtO sterilization and gamma exposure tested per batch.
Documentation that survives an audit. Every insert ships with a material data sheet, molding batch traceability and, on request, a particle shedding report against your spec. Change control covers the tool, the density and the batch, so a validated insert stays validated.
Send TOYOE the component drawings and the cleanliness spec, and we will return a moldable cavity layout with a shedding and compatibility plan.
