EPP molded parts for innovative medical devices

Medical devices are complex high-tech systems that need to be ergonomically designed, precisely manufactured and particularly hygienic. In addition, there are ever-increasing demands on energy efficiency and durability. The choice of material plays a decisive role in optimally meeting all these requirements and increasing ease of use. One material that is increasingly proving its worth in this environment is expanded polypropylene (EPP). Due to its lightness combined with high stability, this particle foam is ideally suited to the manufacture of sophisticated components in medical devices.

The CELLU M6 INFINITY® medical aesthetic device, the lighthouse product in the LPG Systems® product range, is used for mechanical skin and tissue stimulation and analyzes the skin in real time for targeted treatment. As it is used directly on the patient, the device places particularly high demands on handling and comfort.

As an experienced EPP manufacturer, we worked with LPG Systems to develop a customized housing solution based on expanded polypropylene (EPP). The particle foam combines high energy absorption, low weight and thermal insulation properties.

The housing solution is based on our NOVAplex^® design principle. Sensitive components such as motors and sensors are inserted into the precisely fitting EPP molded parts instead of being screwed into place. This is made possible by the high resilience of the material, so that the components are held securely in place.

The housing of the device consists of a total of five EPP molded parts. The high energy absorption of the particle foam ensures that mechanical stresses are reliably absorbed and the sensitive components inside are protected. This reduces the risk of faulty analyses and extends the service life of the device. The overall weight has been significantly reduced without sacrificing stability or resilience.

Simple installation and energy efficiency

The individual molded parts are particularly quick and easy to install thanks to their tongue-and-groove connection. NOVAfeed&fix® fastening elements are also used, which enable the secure and uncomplicated integration of technical components.

Thanks to its excellent thermal properties, EPP reduces heat loss and thus contributes to lower energy consumption during operation. This optimizes the energy efficiency of the appliance.

How an idea became a high-tech product

The CELLU M6 INFINITY® from LPG impressively demonstrates how high-performance product design can be created through co-engineering. Together with the LPG team, we integrated customized EPP moulded parts into the device, significantly improving its function, efficiency and user comfort. We were able to identify technical challenges at an early stage and solve them flexibly, resulting in a product that is modular, easy to maintain and durable in practice.

Functional comparison with the predecessor model with sheet metal housing

The progress is also clear in a direct comparison with the CELLU M6 ALLIANCE®. While the predecessor model still relied on a classic sheet metal housing, the CELLU M6 INFINITY® impresses with a modern housing solution made of EPP and injection molding:

By integrating EPP, we were able to:

• noticeably reduce the overall weight of the device
• improve thermal efficiency and thus protect sensitive components
• Reduce assembly time and increase production quality at the same time