▲ Medical-grade clean, biocompatibility-tested LSR breathing mask cushion produced by Jun-Hsiang
【Technical Challenges】
The breathing mask maintains long-term skin contact and must not release volatile organic compounds during sterilization. Traditional compression molding, with its manual weighing and placement, is prone to dust or operator fingerprint oils. In addition, the complex 3D facial contouring demanded extremely high precision along the mold parting line; any tiny flash would cause user discomfort.
【Jun-Hsiang's Solutions】
Using a fully closed dual-component metering system, raw materials are pumped directly from sealed drums at a 1:1 ratio into the injection unit. The entire process prevents air exposure and human contact, ensuring 100% contamination-free production. We designed a mold with micro-precision parting lines and venting systems, strictly controlling injection parameters to keep flash below 0.03mm. We assisted the client in optimizing curing times and post-curing temperatures to eliminate volatiles, ensuring compliance with FDA 21 CFR 177.2600.
【Mass Production Benefits】
By implementing automated LSR injection, the cycle time per part was reduced from 120 seconds to just 25 seconds, boosting capacity by 380%. The finished product yield reached 99.7%, helping the client capture global medical accessory market share.