Horizon Microtechnologies Explains How Micro-AM Produces Next-Generation Precision Medical Devices

µAM offers several significant advantages in medical applications due to its unparalleled precision and versatility. One of the primary benefits is
its ability to produce highly intricate and complex geometries at a microscale, which is essential for creating devices with the fine details required for some medical applications.

µAM enables the production of detailed structures with high accuracy, which would be challenging to achieve with traditional manufacturing techniques.

In addition, µAM is advantageous due to the fact that in more recent times, materials have become available for use onµAM machines that have passed the relevant tests for

• skin irritation
• sensitisation
• toxicity, cytotoxicity
• pyrogenicity and in vitro haemolysis

They are also sterilisable and are permissible for non-implantable medical applications. µAM also facilitates the customisation of devices to fit specific patient needs, leading to more personalised and effective treatments. The ability to rapidly prototype and iterate designs also speeds up the development process, allowing for faster innovation and time-to-market for new medical technologies.

µAM plays a crucial role in the consolidation of part production by enabling the integration of multiple components into a single build, thus
eliminating the need for complex assembly processes.

This capability is particularly beneficial in medical applications, where the precision and reliability of devices are paramount, and it not only enhances the structural integrity and performance of devices but also reduces the risk of leaks or failures that might occur at assembly junctions.

This consolidation of parts streamlines manufacturing processes, reduces production costs, and accelerates the time-to-market for innovative medical devices.

Horizon Microtechnologies integrates the design and development of 3D microparts with a complete microfabrication production process.

The company combines its µAM expertise with

proprietary coating technologies like

• non-metallic conductive (HMT-Conductive)

• environmentally resistant (HMT-Protect)

• and metallic (HMT-Metal)

These coatings enhance the functionality of

microstructures, including plastics and ceramics,

driving innovation in

applications such as microfluidics, microneedles, and miniaturised surgical tools.

The traditional fabrication of microfluidic devices is often cumbersome

due to the need for multiple complex and precise processes such as photolithography, etching, injection moulding, imprinting, and bonding of different materials, which are not only time-consuming but also prone to errors and misalignments, and in the case of bonding an inability to withstand high pressure.

These conventional methods require cleanroom environments and sophisticated equipment to achieve the necessary microscale features, making the production costly and less accessible.

Horizon offers a streamlined solution using µAM,

integrating the entire fabrication process into a single step followed by coating.

This approach enables the design and precise printing of intricate microfluidic structures in a single build, reducing production time and complexity. It supports rapid prototyping and customization of designs, enhancing efficiency and innovation in microfluidic device development.

Additionally, µAM facilitates the prototyping of short-run injection moulding inserts, reducing product development timelines and accelerating time to market.

Furthermore, Horizon’s HMT protect coating can produce a closed layer on microfluidic channel surfaces, whether they are 3D printed, machined, or
injection moulded.

This separation between the liquid in the channel and the substrate material is advantageous, particularly in enhancing fluid flow
for samples ranging from micro-litres to femto-litres.

It effectively prevents cross-contamination, crucial for maintaining the integrity and accuracy of results in microfluidic applications where capillary forces or surface tension drive liquid movement.

For pressure driven microfluidics bonded devices are often inappropriate due to their inability to withstand high pressure as mentioned above, making µAM a preferred production technology.

Horizon has found the use of µAM for creating miniaturised surgical instruments crucial due to its ability to consolidate parts and reduce assembly efforts.

Traditional manufacturing methods often involve the production and assembly of numerous small, intricate components, which can be labour-ntensive and prone to errors.

µAM allows for the production of complex, integrated instruments in a single step, minimising the need for assembly and thereby reducing the
risk of misalignment or mechanical failure. This integration not only streamlines the production process but also enhances the reliability of the instruments.