Micro-plastic Components - at the push of a button

The starting point - Design follows process
A cerumen filter that can be replaced independently by the user increases the service life and acoustic performance of modern hearing aids. The objective was to develop a filter system suitable for fully automated manufacturing - cost-effective, precise and ready for series production. The filter, smaller than a grain of granulate, is manufactured using micro injection moulding and stands out due to its filigree design and long service life.

The Challenge - Bringing the smallest of parts into full-size view
Implementation placed the highest demands on mould making, automation and the handling of micro components. Particularly challenging were reliable gripping, singulation and inspection of the filters within the defined cycle time. The process was complemented by camera-based inspection, laser micrometer technology and laser marking of the packaging. Tight delivery schedules as well as material changes - including the switch to glass-fiber-reinforced POM - further increased complexity.

The Approach - Perfectly combined
An interdisciplinary team from mould making, robotics and injection moulding developed an end-to-end production concept, ranging from feasibility studies and design optimization to VR simulation and the parallel implementation of tooling and automation. Quality assurance was carried out continuously using sample-based CT measurements.

The Results - A world of sound
Despite a fixed series launch date and ongoing material and design adjustments, the project was successfully realized together with the customer. The high time pressure required the parallel implementation of two production lines - both went into series production on schedule. Today, the cerumen filter system runs fully automated and reliably in production. It exemplifies the successful combination of micro injection molding, high-precision automation and close development partnership.