Body Coils – Innovative tool technology
Initial situation:
The production of body coils, which are used in medical technology for magnetic resonance imaging (MRI), requires precise and reliable manufacturing processes. In order to increase the efficiency and quality of the manufacturing process, the decision was made years ago to change the process and utilise potting technology under vacuum. This method enables greater precision, integration of various functions and therefore has a positive effect on the imaging result.
Challenges:
The development of a new potting mould presented several technical challenges. A key challenge was to develop a mould that was suitable for potting under vacuum and could withstand production conditions at temperatures of up to 130°C. In addition, the mould had to be designed in such a way that it could accommodate different geometries and release them again without damage or material deformation.
A compact and lightweight design was also required in order to be able to transport and handle the mould during production. A further difficulty was to provide the mould with a special surface coating to make the base material more resistant to wear. Finally, the mould had to be designed in such a way that it would have a long service life and ensure series production and the need for spare parts over many years or decades.
Solution approach:
In order to meet the diverse requirements, an innovative, modular casting mould made of aluminium was developed, which is specially tailored to the needs of vacuum production. This lightweight construction enabled easy handling and transportability. All surfaces that came into contact with the potting material were specially surface-coated to increase abrasion resistance. The accuracy of fit of the individual components to each other plays a decisive role. For example, the individual parts have to be moulded into each other in order to minimise the formation of gaps in the cast part and the associated reworking.
Results:
Thanks to the close cooperation with Siemens Healthineers and the use of state-of-the-art production technologies, a highly functional potting mould was developed that meets the high requirements of our customer. The mould has been continuously developed and optimised to ensure seamless integration into the existing production environment, minimise throughput times and maximise the quality of the resulting components.
The modular design and the use of aluminium resulted in a lightweight and easy-to-handle mould that is easy to transport and operate. The special surface treatment has considerably extended the service life of the mould, which significantly increases the reliability and efficiency of series production.
With the new mould, we were able to make the production of body coils more efficient and demonstrate that continuous innovation is an essential part of our work.
