Braunform: Scalable Mold Concepts for the Transition from Pilot to Series Production

4+4-cavity injection mold for Luer connector – (Photo: Braunform).

At Fakuma 2026, Braunform will present mold and production concepts designed to support the transition from product development to validated series production. The focus is on pilot molds whose basic technical principles can be transferred to higher cavity counts and thus to larger production volumes. Exhibits will include an 8-cavity Lift&Strip² pilot mold and a 4+4-cavity RotaricE² pilot mold. Both molds comply with the company’s proprietary MED Mold Standard for medical technology applications.

The concept is based on coordinating part geometry, mold technology and the subsequent production process at the earliest possible stage. During product development, the parts are already analyzed with regard to their suitability for plastics processing and mold design. Simulations and design-for-manufacturing analyses are intended to identify potential risks before mold construction begins and to establish the basis for reproducible production processes.

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32-cavity production mold for insulin pen housings – (Photo: Braunform).

Lift&Strip² for the mechanical demolding of sensitive parts
Using caps for insulin pens as an example, Braunform will demonstrate the Lift&Strip² system both as a pilot mold and as a series-production mold. The patented technology uses a fully mechanical, horizontal demolding process. The molded part is lifted and stripped off in a synchronized sequence of movements.

The combined movement enables direct gating with a valve gate. No additional hydraulic, pneumatic or electric drives are required for the demolding process. This reduces the number of components required in the mold and is intended to increase mechanical robustness as well as the repeatability of the sequence.

The stripping movement is controlled by a cam mechanism. This makes it possible to implement different speed profiles within the movement sequence. This is particularly relevant for thin-walled parts, sensitive geometries or forced demolding, as the load on the molded part during demolding can be controlled in a targeted manner.

An additional ejector stage, synchronized or mechanically coupled, controls two mini-slides. This allows further movement functions to be integrated within a limited installation space. The mold concept is therefore designed for compact applications with high requirements in terms of process stability and part quality.

The pilot mold shown at the trade fair features eight cavities. For series production, scaling up to 32 cavities is planned. The essential mechanical and process-related principles remain unchanged. This is intended to avoid the need to fundamentally redevelop the demolding, gating and movement sequences for the series-production version.

Modular mold concept for product variants and cavity changes
In addition, Braunform will present its patented Flexible Molds Concept. It is based on a modular single-cavity architecture that allows molds to be adapted to different production volumes and product variants.

Standardized modules are intended to reduce the number of different spare parts required. The individual units are designed according to the plug-and-produce principle and can be integrated into the respective mold without extensive modifications. Cavities can be changed directly on the injection molding machine. Easy-to-handle modules are intended to enable short changeover times.

For version changes within a product family, it is not always necessary to replace complete cavity units. Instead, individual cores can be exchanged. Assignment and version control are carried out mechanically or via QR codes. An external unlocking mechanism is used to secure access and clearly identify the variant currently installed.

The concept is aimed particularly at applications involving multiple product variants, fluctuating batch sizes or regular version changes. By reusing standardized mold components, different variants can be implemented without having to develop a completely separate mold concept for each version.

RotaricE² integrates multi-component technology and assembly functions
With the RotaricE² pilot mold, Braunform will showcase another patented mold technology. The concept combines multi-component injection molding, servo-electrically controlled movements and the closing of the molded part within the mold.

Pharmaceutical closure cap with Luer connector – (Photo: Braunform).

In the production of closure caps, this integrates several manufacturing and assembly steps that were previously performed separately into the injection molding process. Downstream handling, assembly or closing processes can therefore be reduced or fully transferred into the mold.

The movements within the mold are servo-electrically driven. This allows positions, speeds and movement sequences to be programmed and monitored in a targeted manner. The functional integration is particularly intended for applications in which several injection molding and assembly operations have to be combined within a limited installation space.

At Fakuma 2026, the RotaricE² system will be shown as a transparent demonstrator. This is intended to make the internal movement sequences, the transfer of components and the final closing operation inside the mold visible.

Validation of complete production systems
The mold concepts presented are part of an engineering approach that takes into account not only the mold itself, but also the injection molding machine, process parameters, automation and the required peripheral equipment. At Braunform’s Technology Center, molds can be tested and complete production systems can be set up and evaluated.

In addition to initial mold trials, manufacturing processes are qualified there and prepared for subsequent transfer to series production. Customer systems, including the machine, mold, automation and peripheral equipment, can be installed at the site. This makes it possible to replicate production conditions before the system is transferred to its final operating location.

The Technology Center is also used for small-series production. Cleanrooms in GMP Classes C and D are available for pharmaceutical applications. In addition to injection molding processes, automated assembly and punching processes can also be carried out there.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall A5, Booth 5207

More information: www.braunform.com

Braunform GmbH, Kunststoff- und Pharmatechnik, Bahlingen, Germany

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