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Exploring the Versatility of Liquid Silicone Rubber (LSR) Moulding for Medical Devices

sam@tcb-arrow.co.uk (Sam Humphries) — Wed, 27 Nov 2024 15:45:00 GMT

Liquid Silicone Rubber (LSR) has become increasingly popular in the medical industry due to its unique properties and versatility in manufacturing medical devices. This blog post delves into the advantages and applications of LSR moulding .

Material Properties

LSR is known for its biocompatibility, flexibility, and ability to withstand sterilisation processes. These characteristics make it an ideal material for various medical applications, ensuring patient safety and product reliability.

Medical Applications

LSR is commonly used in components such as seals, gaskets, tubing, and respiratory devices. Its adaptability allows for the production of complex parts that meet the stringent requirements of the healthcare sector.

Over-Moulding and Thin Wall Capabilities

At TCB-Arrow, we excel in overcoming moulding challenges, including thin walls and over-moulding techniques. This expertise allows us to produce intricate medical parts that enhance device performance.

Meeting Regulatory Requirements

Compliance with FDA/USP Class 6 standards is essential in medical manufacturing. TCB-Arrow ensures that all LSR components meet or exceed these regulatory requirements, providing peace of mind for our clients.

Conclusion

The versatility of LSR moulding offers significant benefits for medical device manufacturing. If you’re interested in exploring LSR solutions for your medical applications, contact TCB-Arrow for a consultation.

The Advantages of Thermoplastic Injection Moulding in Aerospace Applications

sam@tcb-arrow.co.uk (Sam Humphries) — Wed, 30 Oct 2024 15:37:57 GMT

As the aerospace industry continues to evolve, the demand for lightweight, durable, and high-performance materials is at an all-time high. Thermoplastic injection moulding has emerged as a key manufacturing process, offering numerous advantages for producing aerospace components.

High-Performance Thermoplastics

Thermoplastics such as PEEK and Ultem are known for their excellent mechanical properties, thermal stability, and chemical resistance. These materials play a crucial role in ensuring that aerospace components can withstand extreme conditions while maintaining structural integrity.

Key Applications

Thermoplastics are used in a variety of aerospace components, including brackets, housings, and cabin interiors. Their lightweight nature contributes to fuel efficiency, making them ideal for modern aircraft design.

Precision Manufacturing

At TCB-Arrow, we specialise in producing precision components that meet the stringent standards of the aerospace industry. Our expertise in thermoplastic injection moulding ensures that each part is manufactured to the highest quality, enhancing performance and safety.

Case Studies

We have successfully completed several aerospace projects, demonstrating our ability to deliver lightweight, durable components. Clients have benefited from weight reduction and cost savings through our advanced moulding solutions.

Conclusion

Thermoplastic injection moulding offers a myriad of advantages for aerospace applications. If you’re looking to enhance your aerospace components, contact TCB-Arrow today to learn more about our thermoplastic solutions.

Why Plastics?

sam@tcb-arrow.co.uk (Sam Humphries) — Fri, 22 Mar 2024 16:28:27 GMT

With strides being made to move towards greener manufacturing, a common question is “Why do we continue to produce and use plastics?” After all, they don’t have the best reputation as sustainable materials.

However, thanks to developments in the industry, this isn’t necessarily true anymore as more sustainable practices are emerging. This is just one of many of the benefits of plastics in manufacturing, which include:

They’re Non-conductible

Plastics do not conduct electrical or thermal energy well, which makes them great insulators. These insulating properties are what protect us from electrical shocks and burns, and help to keep us safe.

This insulation can help to keep food and drink hot or cold, as it allows heat to be either kept inside or outside of containers - which wouldn’t be possible without plastics.

They’re Durable

When applied to single or short-lived uses, or when plastics aren’t recycled or disposed of appropriately, the durability of plastics can be harmful to the environment. However, the strong and robust nature of some plastics can also be a huge positive when it comes to longer-term applications.

As they can withstand pressure, wear and damage for longer periods of time, certain plastics are actually necessary for long-term or continued use.

They’re Becoming more Sustainable & Recyclable

Despite the fact that many plastics are derived from fossil fuels, the ways in which they can be manufactured are changing and plastics are also becoming easier to recycle.

For example, out of the entirety of the world’s oil production, plastics only use 4% - the rest goes towards transport, heat and energy. Additionally, there are some manufacturers who have experimented with plant-based feedstocks as an alternative and have coined these as Bioplastics.

Although these provide a more sustainable raw material with an almost limitless supply, the wider context of producing Bioplastics needs to be considered (such as the required amounts of chemical and land use, as well as water.)

They are also not always biodegradable, and often need industrial applications to be composted. These are all factors that are important to take into account when considering the use of Bioplastics.

On the other hand, there is an upside to all other plastics: each has the ability to be recycled, provided that the facilities are available and the consumer/manufacturer is willing to do so. Of course, some plastics are easier to recycle than others, as often combined materials are more complicated to break down.

Thermoplastics are the easiest to recycle, as they can be easily shredded, melted and reprocessed. However, there are many other ways in which plastic recycling can be difficult.

Of course, the best way in which to use plastic products overall is to reuse and look after them well for as long as possible, and then finally recycle them when they’re no longer practical to keep. This is something that can be made possible by skilled designers and manufacturers, as they can produce robust and long-lasting materials which are then easily recyclable at the end of their lifespan.

At TCB-Arrow , our experienced team is constantly striving towards the cleaner and greener manufacturing of plastic products. Get in touch with us to discuss your requirements now.

At TCB-Arrow, we have over 35 years of experience in selecting, applying and combining the right additives to achieve the perfect plastic products for our customers. Get in touch with our helpful team to find out more.

3 Helpful Additives That Make Your Plastic go Further

sam@tcb-arrow.co.uk (Sam Humphries) — Tue, 13 Feb 2024 16:12:20 GMT

Plastics are an essential material for manufacturing millions of parts, components and products across the world each year. Sometimes the properties and behaviours need to be formulated in order to serve the right purpose.

This is made possible by introducing additives, which enhance certain properties and help to deliver the desired outcomes to the plastics with which they’re combined. Here are three popular additives which serve different purposes in plastic production:

1. Glass Fibres

Glass fibres are very commonly used in the injection moulding process, as they can significantly improve the rigidity and strength of plastics, helping them to become more robust and resistant to stress cracking.

However, this rigidity also can make plastics more brittle. This means that glass fibres are a great additive for parts that won’t be exposed to a lot of high-impact stress and will have a fairly stable purpose, but not those which endure a lot of pressure or defection.

2. Masterbatches (Colourants)

In order to colour the raw polymers of thermoplastics in the most cost-effective way, masterbatches are added to them at 2%. These are beneficial as they dilute well, allowing for higher levels of accuracy when dosing expensive components.

Another positive aspect of using masterbatches is the fact that they can improve product consistency, as they disperse well and therefore allow for more process stability.

3. Talc

Talc is commonly used in polymer compounds, as its fine particles effectively fill up the inter-particular spaces to increase their stiffness and impact strength. It also provides higher levels of thermal conductivity, which means that the process of heating and cooling plastic compounds becomes quicker. In turn, this then leads to faster production rates.

Talc achieves the highest creep resistance against any other mineral filler, as well as having the lowest hygroscopicity of powdery fillers. This means that it will not take on a high percentage of atmospheric moisture however, in some cases it may still need to be dried before it can be processed.

As each has its own unique set of properties and benefits, the use of any of these three additives in the injection moulding process can help to produce the desired outcome for your plastic part. These are just three of many additives that we use at TCB-Arrow, as we have experience in creating plastics for a wide range of applications.

How TCB-Arrow Works with Optical Liquid Silicone Rubber

Tue, 16 Jan 2024 12:16:51 GMT

Due to its extensive list of beneficial properties, Optical Liquid Silicone Rubber (or OLSR) is becoming hugely popular in the Lighting and Medical markets. From wearable technologies and endoscopes to light guides and medical lasers, Optical LSR combines high-clarity optical qualities with the adaptable nature of polymer-based materials.

But what are these characteristics that make it so desirable? And how do all of these factor into production? Well, OLSR can come with some very specific challenges, which means a lot of facilities avoid it altogether. In this article, we’ll go through all the benefits of OLSR and how TCB-Arrow is equipped to handle its obstacles.

The Benefits of Optical Liquid Silicone Rubber

What makes OLSR unique is that it carries the optical clarity (transparency) of materials such as glass and Polycarbonate, with the incredible versatility of a silicone-based material. This versatility has led to its use in some groundbreaking applications.

It has incredible heat and UV resistance, meaning it won’t yellow over time or break down after long periods of thermal exposure. This makes OLSR ideal for light fixtures as well as a variety of medical applications , where glass or polycarbonate may fall short.

Furthermore, it’s extremely hard-wearing, scratch-proof and has high light transmission, making it ideal for a wide range of applications and increasing its demand. But what challenges does this bring?

Considerations when Injection Moulding Optical Liquid Silicone:

Contamination

Due to the unique applications of OLSR, contamination can negatively affect the transparency of the component, or in some cases, it can make the component unsuitable for medical use.

One cause of contamination can occur when optical grade silicone mixes with a standard silicone whilst being processed. This can cause a murky effect within the components where the visible difference in material grade can be seen. Therefore, making sure that the mixing and metering pump is only used for that specific grade of material is critical to producing good parts.

Another form of contamination happens when particles from the environment stick to the components after they have been produced. To combat this, our team at TCB-Arrow uses ionising air blowers to remove the static charge of the components and prevent any external contamination of the parts.

Process Considerations

When being used for lighting applications, OLSR products must be fully formed and made to the correct dimensions, as any errors will affect the path of the light and could result in an inefficient light source.

To avoid this, the OLSR Injection Moulding machine must be tested regularly to ensure that the process is stable and that there has been absolutely no deviation from the parameters that have been set.

Mould and Part Design Considerations

Due to the fact that OLSR reproduces every aspect of the mould surface, any surface imperfections on the mould must be eliminated before the process begins. In addition to good surface quality, this is a critical step when injection moulding OLSR to improve the refractive index of the product.

Additionally, although the mould design conditions for liquid silicone rubber suggest that the parting line would cross over with the venting areas, it’s recommended that the venting zones for OLSR be on the upper part of the mould. This is due to the low viscosity of the resin.

Contrastingly, the advantage of Optical Liquid Silicone Rubber’s lower viscosity is its ability to reach thin areas of moulds and fill very small cavities, giving the product designer a greater amount of freedom when creating fine features, whilst also allowing for thinner walls on the product.

All of this requires a lot of planning and attention to detail, which is something that we have decades of experience with at TCB-Arrow. Although OLSR has a lot of specific requirements, our team is prepared to meet them–from design all the way through to manufacturing. Get in touch with our team to find out more.

At TCB-Arrow, we pride ourselves on our process. We have the knowledge and facilities to help guide our customers through the design, tooling and mass production of their plastic products. Contact our helpful team to find out more.

Merry Christmas from All of Us at TCB-Arrow

Tue, 19 Dec 2023 11:57:00 GMT

An update on our Opening Times this Christmas.

It’s the most wonderful time of the year, and we’re lucky to have had such a great one at TCB-Arrow . For that, we’d like to say thank you.

To our fantastic suppliers, amazing team and wonderful customers, thank you very much. Have a Merry Christmas, and a Happy New Year! It’s been a difficult few months for many, so it’s time for a very well-earned break.

In the meantime, we wanted to wish everyone a safe and happy Winter break, see you in 2024!

TCB-Arrow is the home of innovative and well-engineered injection moulding solutions. Get in touch now to speak to a member of our helpful team.

We're Hiring

sam@tcb-arrow.co.uk (Sam Humphries) — Tue, 05 Sep 2023 15:06:05 GMT

We're hiring!!

Are you looking for a new role? We're actively recruiting for a range of roles including:

Technician Supervisor
Assembly Operator
Assembly Cell Supervisor
Injection Moulding Apprentice

Visit our careers section to find out more and apply. No agencies.

New Baler Investment at TCB-Arrow Brings us Closer to our Zero Landfill Goal

Tue, 13 Dec 2022 08:00:00 GMT

In our efforts to manufacture more sustainably, we’ve got a new baler for our facility at TCB-Arrow.

Following our installation of solar panels earlier this year, we’ve been considering how to go further with our green manufacturing. This has led to the selection and purchase of our new baler from Orwak .

This has been to aid our recycling of cardboard waste, which is something we get through a lot of as a manufacturing facility. We chose the Orwak 3420 , which produces 26 tonnes and has a cycle time of only 24 seconds!

This mighty machine is making a huge impact at TCB-Arrow, as we’re finding it easier than ever to compress and dispose of our cardboard waste for recycling.

At TCB-Arrow , we’re constantly striving to have a cleaner and greener approach to manufacturing. Get in touch with our team to find out more.

TCB-Arrow Invests in a New Injection Moulding Machine from Negri Bossi UK

Tue, 11 Oct 2022 08:45:51 GMT

Here at TCB Arrow, we’re always working hard to make sure the products and parts we manufacture are delivered to the highest of standards.

This means that we’re regularly reviewing our processes, equipment and machinery to ensure we’re providing a premium service.

This led to the decision to replace one of our older injection moulding machines for a new one, and are delighted to have recently received the delivery.

We now have a new 90 Tonne injection moulding machine from the Negri Bossi Group , which has met our requirements and helped us to keep our production efficient and reliable with our new machine. We’re delighted with its performance and it has made the perfect addition to our facility at TCB-Arrow.

At TCB-Arrow , we have a variety of machines and facilities in order to meet your injection moulding requirements. Get in touch with our helpful team to find out more.

The Advantages and Disadvantages of Injection Moulding

Wed, 21 Sep 2022 14:48:37 GMT

Injection moulding is the recognised process for mass-producing identical plastic products. However, like all the other processes out there, there are many different factors to consider when deciding which is best.

AT TCB Arrow, we’re proud to say we have 35 years of experience in moulded plastics, so we’re familiar with the benefits of each. Here are some for you to consider to help inform your decision:

Advantages of Injection Moulding

It Generates Less Waste - As the only plastic required for this process is forced into a mould, this is naturally a low-waste method of production. If this goes alongside a thoughtful approach to product design and energy-efficient production, injection moulding can lead to a much greener manufacturing process .
Fast Production & Highly Efficient - Injection moulding can produce a very large amount of parts per hour. Depending on the size and complexity of the mould, typically cycle times can vary between 10-60 seconds.
High-Output Production - The speed and efficiency of production means that thousands of parts can be produced before the tooling requires any maintenance. If the demand for a product is high, multiple cavities can be introduced to a tool. This means that, with each cycle, multiple of the same parts are produced.
Quality Consistency - Due to the repetitive nature of injection moulding, all parts produced will be identical. This means that you can rely on high-quality parts being produced en masse.

Disadvantages of Injection Moulding

Restrictions of Part Design - Injection moulding requires certain regulations, and therefore there are some basic rules to follow when designing the plastic parts you plan to manufacture. Some examples of these are:

Avoid sharp edges and undercuts as much as possible
Make sure the wall thickness is uniform in order to prevent inconsistencies in the cooling process
It’s encouraged that you use draft angles as these are better for demoulding

High Tooling Costs - Because injection moulding requires design followed by the manufacturing of the tooling, the up-front costs of the process are high. However, this can be viewed as an investment when weighed against the low production cost.
The Higher The Quantities, The Greater The Benefit - These higher startup costs mean that the process favours high quantities, so if a part you require isn’t in high demand then injection moulding can become a less attractive method. .
Manufacturing A Tool Can Take Time - The initial tooling manufacture does take time which means that the lead times on the first production run can be elongated. This is counteracted when commencing future production runs as once the tool is made the production process is streamlined.

So, there you have some of the advantages and disadvantages of injection moulding. As a greener, more reliable and consistent method of manufacturing, it really is a great way to produce cost-effective and high-quality parts.

uPVC vs PVC

Wed, 07 Sep 2022 13:15:06 GMT

Unplasticised Polyvinyl Chloride (uPVC) and Polyvinyl Chloride (PVC) are each commonly used materials in both manufacturing and construction, but what’s the difference?

Usage

Due to the differences in the durability of each material, they’re most commonly used for different purposes. For example, the more durable and rigid nature of uPVC calls for more uses in construction, such as window frames, plumbing and drainage products.

The softer nature of PVC makes it more suitable for the manufacturing of pipes, cable insulation, clothes and toys. This also is a result of its flexibility, which can make it much easier to work with when it comes to the manufacturing of plastic parts such as these. In addition to its lower cost, this adds to the popularity of PVC moulding.

Properties

Due to the fact that uPVC is highly resistant to chemicals and is strong and stable, it’s often used as a substitute for wood in construction. It’s versatile in the ways it can be produced, so can be made in many different colours and to even appear as other materials, (such as wood,) which adds to its popularity. Additionally, it can achieve smooth inner walls, so it is used for most plastic piping as this helps to encourage water flow.

However, PVC acts as a better replacement for copper and aluminium, as it can be fastened with glue and is easier to cut into smaller pieces. The flexibility of this plastic means that it too can be used for a wide variety of piping, and that larger PVC pipes are often used in plumbing for the distribution of non-drinking water.

Both grades of PVC can be problematic to process when it comes to injection moulding . By its nature, PVC is a heat-sensitive material; temperatures of 160-175℃ are required for the plasticising process.

When PVC is in a melted state, it also becomes reactive to other materials and gasses. A good example of this is PVC and Acetal (Polyoxymethylene). When these two materials are mixed in a melted state, it can cause an explosive reaction.

This added step, therefore, makes PVC harder to work with when injection moulding, so many other facilities choose to avoid it completely. However, at TCB Arrow, we have the skills, resources and capabilities to injection mould PVC in a variety of different forms, making it suitable for a wide range of applications.

Environmental Impact

When it comes to considering the environment, both materials have their perks. Whilst neither plastic is biodegradable, they’re each recyclable and can be reprocessed.

uPVC May just have the upper hand, though: in addition to being a good substitution for wood–meaning it doesn’t contribute to deforestation–uPVC also lacks the plasticisers which can leak out of PVC and cause environmental damage. This makes it the ‘cleaner’ choice of the two.

Conclusion

When it comes to the differences between uPVC and PVC,each has a level of durability that makes them great for piping, but uPVC is definitely the stronger and more environmentally sustainable choice. However, if it’s versatility you’re looking for then PVC is arguably more appropriate, as it has uses in not only plumbing but also fashion and entertainment.

Fundamentally, each performs well in their specific uses as a reliable and sturdy plastic. Whichever you choose will depend on its intended use. However, if it’s PVC you’re looking for, remember that TCB Arrow fully understands and overcomes its challenges due to 35 years of trusted experience.

Having been established for 35 years , at TCB-Arrow we have extensive experience injection moulding a variety of thermoplastics .

We are a modern organisation providing components and assembly solutions in Thermoplastic and Elastomer materials. Visit our website to find out more.

Liquid Silicone Rubber (LSR) Injection Moulding Process Guide

Mon, 09 May 2022 08:00:03 GMT

What is Liquid Silicone Rubber (LSR)?

LSR is a Thermo-Set material, meaning that heat is required to ‘cure’ the material by cross-linking polymer chains (vulcanising). The injection moulding of LSR involves mixing the two-component compound together, which is then heat-cured in the mould with a platinum catalyst to produce a finished LSR part.

The Advantages of Liquid Silicone Rubber Moulding:

LSR is particularly popular for products for the Medical and Automotive industries, due to its good physical properties that include:

A wide temperature range (–50 up to +250 °C)
Very good temperature stability and resistance
Excellent physiological/Hypoallergenic properties
Good ageing and weather resistance (Ozone- and UV-resistant)
Very good dielectric properties
Good clarity/transparency and easily pigmentable if required
Low viscosity that allows the material to flow easily into thin and complex areas of the mould
Suitable for high-volume production
Short cycle times compared to compression moulding (higher production rates)

How does LSR Moulding Work?

An LSR moulding tool is fabricated using CNC machining to create a high-temperature tool built to withstand the LSR moulding process. Due to the flexible nature of LSR, parts are generally extracted from the cavity by air ejection or robot, ejector pins are less common in the mould design.

The material is injected into the tool cold. The mould tool has heater cartridges fitted to heat the tool, enabling the LSR to cross-link (vulcanise) and solidify. Insulation plates prevent heat loss and ensure the heat is contained in the tool. This step is called the curing stage, dependant on the silicone grade used and the section thickness of the part.

Unlike conventional thermoplastic injection moulding , LSR injection moulding requires little to no holding time, and the cavity only needs to be 90-95% filled. Cavity pressure is created by the expansion of the LSR as it cures, providing the finished part surface finish. This is shown below:

For more information on the liquid silicone rubber (LSR) moulding process or our other plastic injection moulding services, visit our website .

The Advantages of Injection Moulding

Fri, 29 Apr 2022 14:46:19 GMT

At TCB-Arrow, we are specialists in the precision manufacturer of injection moulded parts, with a wealth of experience providing solutions across all market sectors including Aerospace, Automotive, Industrial and Medical industries.

But why is plastic injection moulding so popular across such a wide range of industries, and why is it one of the most commonly used methods of producing identical plastic parts in high volume?

Take a look at these advantages of plastic injection moulding to understand why it is so popular:

Enhanced Strength

The strength and durability of plastics has increased immensely over the years. Today’s range of Thermoplastics can withstand even the harshest environments, making them as strong, or if not stronger, than metal parts. The physical attributes of a part will be determined in the design process, based on understanding the application and environment it will be used in. With over 25,000 engineered injection moulding materials to choose from, plastic can be moulded to be as flexible or rigid as required.

Complex Plastic Part Design

Injection moulding can create extremely complex parts, and produce them in high volumes with accurate repeatability. As one of the most versatile manufacturing methods, Injection moulding can produce parts for all industries. The key to consistency is precision tooling and tight Moulding process control using machine monitoring setup by skilled Process Technicians.

Colour Control

Plastic parts can be manufactured in any required colour with the use of masterbatches or compounding. 2shot+ technology means that materials and colours can be moulded simultaneously and chemically bonded during the moulding process while keeping the structural integrity of the product.

Green Possibilities

Plastic injection moulding is actually more environmentally friendly than many assume. From optimising the item’s physical properties and material content to make it as economical as possible to using environmentally friendly materials with higher sustainable and reprocessed content, at TCB-Arrow we do all that we can to make our injection moulding process greener. Aside from the moulding materials used, injection moulding is an intrinsically low-waste process. Items are designed to optimise the physical attributes of a part with the least material content using CAD design programs to achieve this.

Efficiency

Injection moulding is commonly referred to as the most efficient form of component manufacture. Production output depends on the complexity/size of the part and the size of the tool (number of cavities), cycle times can vary from 5-120 seconds. Once a product is designed and the tool is made, large-scale production of items is possible with Mould tools usually typically having a production life of millions of cycles.

As specialists in the precision manufacturer of injection moulded parts, we produce bespoke technical parts to our customers’ design and specification. We work closely with our customers, from initial concept through to product realisation, to maximise efficiency and produce high-quality products.

How Can Injection Moulding be Greener?

Mon, 04 Apr 2022 08:00:08 GMT

With the government committing to cutting the UK’s emissions by 78% by 2035 in an attempt to reach the net-zero carbon target by 2050, living greener and more sustainably is a hot topic.

Plastic injection moulding is a process that has gained a bad reputation for its green standards, and many think that the two could never go hand in hand. But that’s where you are wrong - at TCB-Arrow we are committed to ensuring our products and processes are greener, and we do so in a number of ways.

Design

We assist customers with the design of products in order to optimise the item's physical properties and material content, ensuring the material content is as economical as possible. This is achieved by making sure the section thicknesses of the part provides the necessary strength while not being too thick. If parts are made too thick, they take longer to cool, meaning the cycle time is longer and the production process is not optimised.

Materials

Not only do we evaluate the amount of material used, but also the ratio of Prime (new) to Reprocessed material. We try to use environmentally friendly materials for our projects where possible, with higher reprocessed content. Over 50% of the materials we use are reprocessed grades, which equates to over 30 tonnes a month.

Manufacturing Process

Aside from the materials themselves, the process of injection moulding is inherently low waste, and at TCB Arrow we have optimised our processes to reduce waste and improve efficiencies. By operating more efficient processes, cycle times are reduced, which in turn reduces direct energy cost per component, leading to higher output with less consumed energy. Current injection moulding machines are more environmentally friendly, so we regularly replace machines with the latest energy-efficient equivalents, to ensure we are producing with the least CO2 impact possible.

Optimising Our Factory

In terms of the space we operate in, we are doing all we can to ensure we are as environmentally friendly as possible. We operate a 24-hour shift system, meaning we can keep our machines running constantly, reducing any downtime and contributing to our high efficiencies. We are very conscious of the source of our electric supply and we endeavour to source our power from suppliers with a high sustainability content.

We are also aiming to become more self-sufficient, producing our own energy through solar PV panels. With this £100,000 investment, we expect to see a full ROI within 5 years due to the amount of energy saved and instead produced through our own solar energy.

Having been established for 35 years , at TCB-Arrow we have come a long way in terms of improvements in our environmental footprint and commitment to minimising the impact of our activities. It is our environmental consciousness that drives us to continually review and reduce our ecological footprint, and these are just some of the ways we are currently striving to do that.

We are a modern organisation providing components and assembly solutions in Thermoplastic and Elastomer materials. Visit our website to find out more.

Five Industries that use TCB-Arrow Plastic Injection Moulding

Mon, 21 Mar 2022 09:00:04 GMT

Plastic injection moulding is one of the most versatile manufacturing methods available, used by a wide range of industries to produce various parts.

From small to large parts, plastic injection moulding mass-produces cost-effective and high-precision parts. As an established organisation that has been around for over 35 years, we offer solutions across all markets including Medical, Aerospace, Automotive, Defence, Industrial market sectors and more. In this blog, we take a closer look at the products we produce for five different sectors.

Automotive

While the automotive industry has seen a lot of change over the last decade or so, one thing that has remained constant in the industry is its use of plastic injection moulding. We regularly supply products such as ignition leads, automotive insulator boots, seals and grommets, as well as car number plate components, of which we produce over 4 million each year. Plastic injection moulding allows for these items to be mass-produced to a high quality.

Food and Drink

Many products used in everyday life are made through injection moulding, and that includes products for the food and drink sector . From vending machine components such as cup delivery systems to simulant devices and anti-spill drink covers, at TCB-Arrow we supply an array of products to the food and drink sector.

Medical

We manufacture single-use disposable and reusable parts in both LSR and Thermoplastics for the medical industry . These include stoma care products, enema connectors, eye shields and airway management components. During the pandemic, we also helped by producing PPE, developing a clinical and general applications PPE visor shield.

Banking Security

We work closely with the security industry to produce components for banking security devices . We are experienced in producing products such as security system components for ATM banknote cassettes.

Industrial

Our experience in producing high tolerance parts, material selection and complex tooling means we can produce parts for the industrial sector . We recently produced RFID tags for a customer so that they could put an asset tag on all equipment to track its movements in and out of site. In addition to this, we produce conversion film end protector plates, pallet corner protectors and articulated protector tracks for robotics.

These are just a few examples of the industries we work with, however, the possibilities with plastic injection moulding are endless. Our list of industries is growing more and more as companies realise the benefits of this method of production.

If you have a question or query, please get in touch with our 24/7 production facility and one of our experienced team members will be happy to help. If you are looking for a price, please complete our Quote Request Form .

TBC-Arrow Invests in an Agie Charmille EDM Spark Eroder to Enhance the Toolroom Department

Mon, 21 Feb 2022 09:00:09 GMT

To further enhance our Toolroom department, we have recently invested in a new Agie Charmille EDM Spark Eroder to replace an older machine.

TCB-Arrow Invests in a New Kraus Maffei 300t Injection Moulding Machine

Mon, 14 Feb 2022 09:00:15 GMT

We are proud to announce that we have now invested in a new Kraus Maffei 300t Injection Moulding Machine, the latest generation injection moulding machine based on proven two-platen technology.

This machine will replace an older machine in our mouldshop, allowing us to ensure that all of our machines are reliable, efficient, and up to date with the latest technology.

We chose the Kraus Maffei 300t Series for a number of reasons. Firstly, the MC5 control allows for a simple and fast job setup. The machine has extensive functionality to control a wide range of machine movements and reliable monitoring, as well as evaluation programmes, which will give us accurate and precise control to optimise the quality of products for our Customers.

New Machinery Investment: The Baty Venture 3030 CNC (CMM Machine)

Mon, 07 Feb 2022 09:00:08 GMT

We are excited to announce that we have invested in the latest generation of vision inspection machines, the Baty Venture 2020 CNC (CMM Machine).

Additional features of the Venture 3030 include:

Extended Z axis measuring 200mm, with a new integral counterbalance and a revised Z axis lens.
Increase field of view and up to 12x magnification.
Optimised use of a Renishaw touch probe, including the ability to fit a probe charger rack so that probe modules fitted with a variety of pre-calibrated Renishaw styli can also be used in the same inspection.
Advance software with features including a self-calibrating zoom lens and improved autofocus.

COVID-19 Operational Statement

Thu, 19 Mar 2020 11:17:32 GMT

The situation is continually changing with government policy developing daily.

Although to date TCB-Arrow Ltd have not had any disruption in supplies or operationally we have been actively putting in place measures aimed at reducing the impact of COVID-19 and comply with Government advice.

Full statement available here .

Keep up to date with the operating status of TCB-Arrow by checking our website regularly.

Stick+Store Dual-Bladed Duo Squeegee for InHouse

Fri, 15 Nov 2019 15:29:57 GMT

TCB-Arrow have been working with product inventor Steve Briton-Williams to produce a Dual-Bladed Duo Squeegee for InHouse's Stick+Store shower products range.

TCB-Arrow has successfully helped product inventor Steve Briton-Williams develop an additional Duo Curved and Straight shower Squeegee to join his current range of InHouse Stick+Store shower products. The first pallet of 1,000 parts were manufactured, packaged completed for dispatch to Lakeland on the 10th October 2019. The new product launch took place on the following Monday and by later that week it had jumped to Lakeland’s No.1 spot by product type!

This Duo Squeegee now complements the smaller Mini Squeegee and Larger Squeegee. The whole range has a clever patented integral suction cup system to keep it where you need it, with a comfortable soft-grip handle. The design includes two blades instead of one; the first a conventional flat blade very much like the other sizes in this range. The second one is carefully curved to cope with curved shower screens and doors. Its soft double blades also help clear water droplets from tiles, mirrors, windows, flexing as they travel over the surfaces you’re cleaning, to ensure not a drop or scratch will be left behind.

TCB-Arrow specialise in over moulding in both thermoplastics and liquid silicones, working to tight tolerances and high cosmetic finishes. TCB-Arrow strengths are working with customers from initial concept through to full production. We love the challenge of new plastic moulding projects! Don't hesitate to get in touch on 01276 679394 .

TCB-Arrow Warehouse Re-organisation

Fri, 15 Nov 2019 15:29:47 GMT

Additional Warehousing space created by re-configuring the warehouse layout and introducing a narrow aisle forklift

Following significant growth in our business over the last 12 months we were starting to struggle with a shortage of warehouse space. Having undertaken a full review of our current setup, we identified that we could yield a further 100 pallet spaces by introducing a narrow aisle racking system and investing in a new Flexi forklift suitable for operating in narrow aisles. This would mean that we could avoid taking on additional overhead burden for the business.

We completed the reorganisation over a weekend to minimise disruption. With the additional storage we have been able to free up space around our facility and are already seeing a benefit right around in operational efficiencies.

GPS Golf Wrist Strap for Shotscope

Fri, 31 May 2019 13:42:26 GMT

TCB-Arrow have been working with Shotscope to produce Liquid Silicone Wrist Straps for their new high-tech Golf GPS device.

Shotscope are a company that have designed and manufactured a best-in-class Golf GPS device. Using the in-built GPS in combination with an RFID reader, the watch is able to identify which club the golfer has in his hand and the GPS location at which the club strikes the ball. From this information and a library of mapped courses, the watch builds a picture of the golf round. Once complete the data can be downloaded to the user account and the game analysed and compared against previous games by the user. This provides analysis on each club and can also compare performance against other golfers.

This is a fascinating and high-tech product and when Shotscope approached TCB-Arrow to manufacture the Liquid Silicone Wrist straps for the device, we were very keen to get involved and apply the experience we have built up over many years moulding Liquid Silicone Rubber (LSR).

The part design itself involved significant challenges, as we needed to overmould a flexible RFID antenna with the LSR. The board itself is over 100mm long and can only be supported at the ends, so we needed to ensure that there was a consistent section thickness of LSR moulded over its surface. We overcame this challenge by creating a 2 stage moulding. The primary overmould was designed to provide a skeletal perimeter to the board that could then be held more rigidly in place in the second overmould.

In addition to this challenge, the customer had the requirement for a moulded seal to prevent water ingress at the point the flexible PCB enters the watch housing. We suggested that this could be overmoulded directly onto the board in the primary overmould process. This we achieved using a secondary runner from main moulding to feed the seal. The seal can be seen as the green component in the 3D image below; the primary overmould is the blue area over the flexible circuit board (in brown).

This was an exciting project to work on, and we are always open to considering even the most unusual and complex plastic moulding projects! Don't hesitate to get in touch on 01276 679394 .

Team Expansion at TCB-Arrow

Thu, 30 May 2019 00:00:00 GMT

We are excited to be welcoming multiple new members to our team, in order to facilitate the significant growth in our business over the last few months.

Our new positions include:

Our new Toolmaker, to support the additional tool making and maintenance activities
A new Quality Engineer, to support the new part validations and capability studies required for the new products
Three new Moulding Technicians, ready to enable us to run 24/7 with adequate shift cover
Six Machine Operators to ensure all shifts are adequately staffed to cover all tasks

Employing more staff is essential to keeping the workload reasonable for each individual, ensuring workplace satisfaction and quality results. At TCB-Arrow we appreciate every employee and the huge difference they make to creating a fantastic and efficient working environment, and we can't wait to see the huge benefits that our new team members will bring.

Best Wishes to Viv on her Retirement after 23 Years at TCB-Arrow!

Wed, 29 May 2019 00:00:00 GMT

Last month saw us saying goodbye to Vivien Parker on her retirement. After 23 1/2 years of loyal service,
Viv decided it was time to retire. She has worked in the business as an operator and assembler and has
over the last few years been predominantly working in our clean inspection and packing room. She has
seen our business go through a huge transformation over the years into the technical moulding operation
we have today.

We wish Viv all the best wishes for her next chapter.

What are Design For Manufacturability (DFM) Reviews and Why are they Important?

Mon, 27 May 2019 00:00:00 GMT

DFM is an engineering review to evaluate the manufacturing feasibility of a product design along with addressing and highlighting any manufacturing concerns that might be evident from the design prior to proceeding with tooling.

During this review phase there is also a potential opportunity to reduce manufacturing costs by illustrating the general tool layout and highlighting any complex/costly tooling ancillaries i.e. side actions, mould lifters etc that are required to achieve the level of design being analysed. The customer then has the opportunity to adjust their design to negate the need for these ancillaries which in turn can help reduce overall manufacturing costs. The DFM Review is the most informative and efficient method of evaluating any part design prior to tool manufacture. At TCB-Arrow the DFM Review is a key stage in our New Product Introduction (NPI) Process.

In general, there are many critical aspects of a part design that are reviewed during a DFM. These are as follows:

Suitable materials to consider for the part application and their applicable mould shrinkage allowances
Tool/part split line positions
Optimum gate feed position and type
Ejection style and positions
Wall section thicknesses
Potential levels of distortion and sink
Draft angle and venting recommendations where required
Surface finishes
Part tolerances and areas to leave “metal safe” for dimensional adjustments once tool manufactured.

These are just some of the key points covered during our reviews.

To help illustrate these points please see below a selection of pages from a few of our DFM first stage reviews for parts to be manufactured at TCB-Arrow:

In conjunction with any DFM review an Advanced Moldflow Analysis can also be undertaken to help optimise a part design. These types of analysis are often performed if there are:

Part material selection issues
Thickness / Thinness problems
Structural concerns, for weld line controls, residual or structural stress issues
Filling concerns
Product function requirements
Sink or appearance concerns
Cooling channel optimisation for reduced production cycle times and distortion

To help illustrate this type of analysis please see below a selection of pages from a typical TCB-Arrow Mouldflow Analysis:

In summary, both DFM & Moldflow Studies are very useful tools to assist in identifying aspects of a part design that are likely to be problematic at the moulding stage. These reviews provide the opportunity to make the necessary changes in tooling and part design to prevent moulding issues.

Please don't hesitate to get in touch with our expert team on +44 (0)1276 679394 for more information on how we could facilitate your project.

TCB-Arrow's Continued Commitment to Investing in Our Business

Fri, 24 May 2019 00:00:00 GMT

To enable us to remain efficient and provide the level of service and product quality, we are required to continually invest in our business. At TCB-Arrow we keep a log of all the investments we have planned and completed. We take great pride in this as it demonstrates our long-term commitment to our business, customers and all stakeholders.

In the last year we have invested over £240k in new plant and equipment and over the last 4 years this investment is in excess of £550k.

In the last year investments include:

5 new injection moulding machines
1 new 3 axis robot
1 new centralised chiller
1 new pad printer
1 new ultrasonic welder

Please don't hesitate to get in touch with our expert team on +44 (0)1276 679394 for more information on how we could facilitate your project.

The TCB-Arrow Core Processes

Thu, 02 May 2019 12:45:01 GMT

TCB-Arrow’s Quality Management System

Traditional quality management systems are paper folders, not connected to the business, and barely looked at.

TCB-Arrow’s system is designed to be an integral part of the business to prevent deviation from process.

Contract Review

Customer order receipt
TCB-Arrow order review and acknowledgement (price review, production lead time review, delivery date)

NPI - New Product Introduction

This process ensures we capture customer product specifications and expectations consistently
Process capability studies are part of TCB-Arrow’s NPI process. Generally we take 30 consecutive shots from a new mould tool and statistically review their dimensions to look at standard deviations versus dimensional tolerance. CPK value above 1.33 is a general requirement. This is not a necessity of the ISO standard but it is a fundamental part of TCB-Arrow ensuring we exceed customer expectations.This NPI validation process is aligned with recognised FDA standards.

Product quality control

This process ensures we manufacture products to the agreed specification.
Traceability - we capture both materials and operator information against each production works order in our MRP software to ensure we maintain full product traceability.
First off and last off samples are retained from every batch run and inspections carried out throughout the process including SPC measurements of critical dimensions.
Materials, operator and inspection results are available and encorporated into a final certificate of conformity to accompany goods as required by customers.

Document Control

This is an important process to ensure that we capture and control any document changes within the business. This includes customer issued drawings, internal drawings, procedures, policies etc
Our real time documentation system puts everything on hold if a customer advises that they are updating any released documents, through to re-release
The improvements log maps significant improvements and the investments that the business has made. It demonstrates long term commitment to the future of the business.

TCB-Arrow to Introduce Anti-Microbial Additives to Fight Bacterial Growth

Thu, 08 Nov 2018 14:15:21 GMT

In an effort to prevent bacterial growth on certain products, we are beginning to introduce anti-microbial additives. Our supplier provides us with fast, effective and permanent protection against bacterial growth thanks to its specialist anti-microbial technology, which helps to reduce the risk of cross-contamination.

But first, what is anti-microbial technology? Simply put, it’s a substance that destroys the presence of bacteria, or mould. By being built into the foundation of the product itself, the anti-microbial can then go on to prevent the growth of microbes such as fungi that would otherwise cause contamination. The supplier used by TCB-Arrow employs a particularly potent brand of the technology - bespoke additives that enforce a permanent, inbuilt protection.

At TCB-Arrow, the quality of our products is of absolute importance. That’s why we’re taking the additional steps to prevent any kind of risk - products like sanitary bins or shower squeegees are being given the new technology, which protects them against invisible dangers. The additive technology is seamlessly integrated into the manufacturing process, making it easy for us to incorporate it into our products. From there, it goes on to become a part of the finished product, helping to protect it from harm. The anti-microbial additive technology protects the product for its lifetime, keeping its surfaces clean and hygienic.

To learn more about how we use the cutting edge anti-microbial additives within our products, get in touch on 01276 679394.

Two New Krauss Maffei Machines Brought in to Help with High Production Demand

Wed, 10 Oct 2018 11:06:20 GMT

It’s an exciting time at TCB-Arrow. High demand for our products has meant that we’ve had to expand our production capacity even further. Earlier this year we mentioned that we’d purchased three brand new Krauss Maffei machines to help take us through 2018 - now we’ve purchased two more.

The machines in question are an 80 tonne and 50 tonne Krauss Maffei moulding machine, both of which were brought in to help with the increased demand. TCB-Arrow is currently having to run 24 hours a day, 6 days a week to keep up - it’s been busy! The new Krauss Maffei machines will continue to enable us to be even more efficient. The machines feature Servo driven hydraulic pumps, meaning we’ll continue to save energy over the machines we previously used. This means the machines give us a commercial advantage, this of course is passed on to our Customers.

The machines are incredibly accurate. Injection volumes and speeds are controlled with such precision that we can achieve injection times between shots that are consistent to within 0.01 seconds. The variable settings can then be saved in the machine SSDs or on USB sticks and transferred between machines, for maximum efficiency and reducing setup time. For more on how our new Krauss Maffei machines will enable TCB-Arrow to consistently deliver on the high demand expected of our production service, make sure to read our previous blog .

If you’re interested in learning more, get in touch with a member of our team on 01276 679394.

The Early Days of Plastic - How it Changed the World

Thu, 19 Jul 2018 16:23:23 GMT

There has been no material more revolutionary than modern plastic. Used in almost every single industry in a vast range of ways thanks to its versatility, high durability and ability to be molded into whatever shape necessary, no material has changed (and in many ways, shaped) the world like plastic has.

As far back as 1869, John Hyatt, in his search for a substitute for ivory, discovered that plastic could be molded into a number of different shapes, while imitating natural substances. However, modern plastic first came about in 1907, when bakelite was invented by Leo Baekeland - it was modern in that it was completely synthetic. There were no natural molecules in it. Throughout the 1950s and 60s, production costs lowered dramatically, paving the way for the mass production of household plastic items.

Since then, plastic took over the world. Thanks to its ability to remain sterile while acting as a container, plastic was used in the formation of bottles for items such as milk, which no longer had to be delivered in glass bottles. In the food industry in particular, plastic has had an amazing, incalculable effect. Raw meat can be kept in plastic packaging to prevent potential diseases, while the use of plastic trays to keep food fresh has actually helped to diminish waste in stores.

Plastic has had a profound impact on almost every industry it has touched. Medicine benefited greatly from the development of the disposable plastic syringe in 1955, for instance. In fact, if we were to swap plastic for any other material to be used in the same way, it would exponentially increase greenhouse gases being emitted. The effect plastic had on the nascent industrial world cannot be denied.

Today, plastic is still used heavily in almost all industries as one of the most reliable and versatile materials around. Get in touch today to find out more about the plastic industry and what we can do for you on 01276 679394.

Putting Plastic in the Spotlight - How it Benefits Industries

Wed, 13 Jun 2018 00:00:00 GMT

Plastic is often the recipient of a lot of negative attention, but the fact of the matter is that as a material, plastic has allowed for countless innovations and advances within a huge range of industries across the world. Thanks to its many positive properties, such as being lightweight, durable and resistant to all manner of dangerous and potentially damaging chemicals, plastic is the go-to material for a number of different industries.

Packaging

Plastic is used to package all kinds of things, from food to medicine and even acids. The numerous beneficial properties of plastic make it perfect for the packaging industry - it can be moulded into whatever form necessary, while retaining its durability. This means that plastic is an incredibly versatile material and suitable for a whole range of different packaging. Plastic containers are used for household items, but they’re also used in the medical industry thanks to their extremely high durability against some corrosive materials. This means it’s used for hazardous waste disposal.

Transport

Plastic is a very popular material to use in transportation as it is easily coloured and highly durable. Thanks to the relative light weight of plastic, manufacturers were able to make vehicles lighter overall. This in turn meant cars and aeroplanes for instance became more power efficient and much easier to look after. Meanwhile, in the public transport sector, plastic can be found everywhere from seats to interior panels.

Construction

Plastic is absolutely essential within the construction industry, where it is used heavily in plumbing fixtures and piping. Plastic is also used throughout the home, in windows, flooring, panels and so much more. Plastic is used in the construction industry thanks to its ability to resist natural elements well, meaning it holds up both inside and outside of buildings. Plastic’s relatively low weight makes it suitable to be moved and carried during the construction process.

We’re able to see then that plastic, thanks to its many beneficial properties, is put to great use through a wide range of industries that involve items we use on a daily basis. At TCB-Arrow, we use plastic in a number of different industries - if you’re interested in seeing what we can do for you, get in touch on 01276 679394 or email us at enquiries@tcb-arrow.co.uk .

Investment News

Wed, 04 Apr 2018 13:38:47 GMT

Value added with the introduction of further new services for 2018

“In line with our continued investment plans we have taken delivery of a new Ultrasonic Welding Machine to complement our existing portfolio of core business services. It is aimed at creating more capacity and driving current standards even higher, thus demonstrating further continued commitment within the business and towards a growing customer base.”

Murray Humphries (Managing Director)

Efficiency, Control and Repeatability

The Ultrasonic Welding process benefits by using the part material itself to form a bond and does not introduce any additional materials such as glues or adhesives into the device. It is a fast, clean, efficient and repeatable process, ideal for joining just about any set of plastic parts in many applications, from simple structural bonds to more complex hermetic seals.

This latest machine is very accurate in operation, equipped with PLC which controls electronic and pneumatic operations, achieving excellent repeatability between cycles. Therefore having set the machine for a particular component, there’s no need to thereafter interfere or reset for that item as all of the variable settings are stored, which in turn equates to valuable savings on setup times.

Ultrasonic Welding Case Study

TCB-Arrow were recently approached with an ultrasonic welding enquiry where the client was sourcing finished welded product through a Far East supplier, but due to ongoing quality concerns they felt there was a need to transfer the welding process of the product to a local UK supplier in an attempt to establish an improved level of quality control for their finished product.

The product itself consists of a PC/ABS upper and lower case containing a sealed RFID tag system. The specification stipulated was that the finished cases are manufactured, sealed and validated to an IP68 rating.

TCB-Arrow took onboard the client’s comments and concerns with their current supplier’s crude air tight validation process of submerging the parts in a water tank at a set depth over a prolonged period. This was followed by deconstructing the cases for visual inspection of water ingress, which deemed the cases to be inadequate to qualify the rating.

With these points in mind we developed an efficient and repeatable new style of pressure test, where a live push-in style, pneumatic connector fitting is threaded into the underside of the lower case. The welded unit is then submerged in a water tank and pressure tested for leaks incrementally, utilizing a regulating pressure gauge to a calculated acceptable internal pressure reading of 0.5Bar, then beyond to the point of destruction periodically throughout a 5k production run. Using this new method, accurate pressure test results were obtained and recorded as real time SPC data during the manufacturing process, bringing the test in line with industry standard methodology.

This technique of validating and testing the welded cases level of Hermetic seal has proved to be far more efficient and controllable than our clients previous test, in fact since introducing the new test a 100% pass rate has been recorded for all RFID tagged cases now ultrasonically welded by TCB-Arrow.

3 New Krauss Maffei Machines for 2018

Tue, 13 Mar 2018 14:53:44 GMT

In line with our continued investment plans we have just taken delivery of 3 new Injection moulding Machines to complement our existing equipment. These consist of a 130 tonne and two 80 tonne Krauss Maffei machines. In the last 3 years we have invested over £500k in new plant and equipment, demonstrating our continued commitment to our business and customers.

Efficiency

With Servo driven Hydraulic pumps on all 3 machines, we expect to see a 40% energy saving over older machines. This is not only in line with our environmental policy and objectives, but it provides a real commercial saving that we will pass onto our customers putting us at a competitive advantage.

Control and Repeatability

These new machines are very accurate in operation. Injection volumes and speeds are so accurately controlled that we are able to achieve injection times between shots that are consistent to within 0.01 seconds. Combining this with very accurate injection volumes through screw positions measured to 0.01mm, we achieve excellent repeatability between cycles. All of the variable settings are saved in the machine SSDs or on USB sticks; these can then be shared between machines, ensuring that jobs can be put up and repeated accurately from batch to batch, also saving valuable setup time.

Quality Control and Validation

With many of our customers requiring process validation studies to be performed, we comfortably achieve these tight validations through machine accuracy and repeatability. We work to FDA process validation formats, conducting Installation, Operational and Production Qualification Validations (IQ, OQ & PQ). Within these studies we output a measurement of process stability that takes 3 standard deviations of the measured critical dimensions and weights - it then applies these to tolerances that are generally tightened considerably up on those defined by the customer. Once we have approved the process then we set Quality Parameters on the moulding machines to ensure that any slip in the process causes the machine to alarm well before unacceptable parts are produced.

Four Benefits of Using Plastic in the Medical Industry

Fri, 09 Mar 2018 00:00:00 GMT

Plastic is one of the most widely-used materials on the planet, favoured for its versatility and cost-effectiveness, which allows it to be used in all manner of applications. In the medical industry , different variations of plastic are enabling healthcare providers to ensure that patients continue to receive a high quality of care, while cutting costs along the way. These are just some of the benefits of using plastic within the medical industry.

Infection Resistance

Plastic has greatly improved safety in the medical industry, where good hygiene is of paramount importance. The inherent sterility and inertness provided by plastic helps stop the spread of diseases in hospitals, so it’s no surprise that many different items found in the industry are plastic - bedpans, IV tubes, syringes and eye patches to name a few. Specifically, antimicrobial additives in the polymer can help to repel and kill bacteria on exposed surfaces.

Containment and Safety

Thanks to the aforementioned hygienic properties of polymers, mouldings make excellent containers and material handling devices. But it’s more than just its sterility – many plastics can resist incredibly hazardous substances, while also being far safer to transport than something like glass, which has the potential to shatter. Plastics can also help to preserve the integrity of a container’s contents, making them ideal for protective coverings.

Cost-Cutting

Plastic devices are generally cheaper to produce than metal ones, due to cycle times (production rates) and material cost, plastics parts and components are saving people money all across the industry. These reusable plastics are easier to replace and have a longer life than single use metal devices.

Innovation

Plastic technologies are enabling engineers and medical inventors to create new devices from the smallest micro-moulded parts. Thanks to this, plastics are being used in surgical devices and procedures, and are being used more and more in devices such as pacemakers, joint replacements and stents.

If any of our services within the medical industry or other industries are of interest, don’t hesitate to get in touch on +44 (0)1276 679394 or drop us a message on enquiries@tcb-arrow.co.uk.

How Does Plastic Make Sport Possible?

Fri, 20 Oct 2017 09:34:56 GMT

At TCB-Arrow we manufacture a huge variety of plastic products for multiple industries, from the medical and hygiene sectors to the aerospace and automotive fields. The versatility of plastic means it is imperative for the development of these industries and more, however one field that is not as recognised as needing plastic in its various forms is sport.

Plastic sports gear has only been around for six or seven decades, but its success exponentially increased as its benefits became recognised. But why the change from leather to plastics?

Helmets

The lightweight, shock-absorbing yet tough elements of plastic made it the perfect material for helmets; foam plastics can create the compressible layer on the inner of the helmet, whilst the tough outer layer of a helmet can be specifically customised for the sport it is designed for.

Goggles

Plastic eye protection is essential for extreme sports, its lightweight, transparent and nearly unbreakable factors perfect for preventing dirt, debris or weather conditions making many extreme sports possible. Even the stretchy, gummy material used to keep swimming goggles in place and waterproof uses plastic polymers.

Padding

Sports such as mountain biking, BMX and freestyle stunting (on skateboards, bikes or anything else!) require proper protective padding. Athletes are constantly challenging themselves to more extreme and dangerous stunts, so plastic is simultaneously developing new plastic pads to provide comfort and safety even in the most dangerous sports.

Gear

With athletes pushing themselves harder and further, their gear needs to echo this, both for optimum performance and safety. Sports gear is getting lighter, with Usain Bolt's running shoes weighing less than an average apple. Wooden tennis rackets now in the past, the high-tech fiber-reinforced frames and tough nylon strings mean Federer's serves can be over 150 miles per hour.

Clothing

Think about pro athlete swimsuits, ski-suits, cyclists' lycra and even pro football jerseys. Each have been developed with polymers to have optimum properties for the conditions of the sport. These improvements at some points became too much: swimsuits made with polyurethane foam provided so much of a competitive edge by reducing drag and improving buoyancy that the international community now disallowed them!

Although TCB-Arrow do not focus on sport-themed plastic production, we are constantly increasing our awareness on the development of plastic properties in all industries. Get in touch on +44 (0)1276 679394 or drop us an email at enquiries@tcb-arrow.co.uk to have a discussion with our expert team on what we can do for you.

The Positive Impact of Plastic

Mon, 18 Sep 2017 09:12:17 GMT

Plastic is an incredibly versatile material with a huge range of applications due to the multiple forms, textures and strengths it can take. There are many positive impacts of plastic on the environment that are generally unrecognised, so here are a couple of benefits that you may be surprised to hear:

The Automotive Industry

Metal replacement programs have drastically improved the fuel efficiency of vehicles, with the most efficient vehicles utilising lightweight plastics to deplete the vehicle weight. It is estimated that every 10% weight decrease results in a 7% decrease in fuel usage. The use of plastic in the automotive industry has not only benefited the environment but has also improved design potential, vehicle safety and vehicle life.

Insulation

Plastic home insulation cuts a major source of heat loss, with polystyrene widely recognised as an excellent insulating medium. As a lightweight, rigid and cheap plastic material, it is a very immediate and affordable means to fight climate change. The results of a Denkstatt study (2010) showed that the total lifecycle of polystyrene insulation consumes on average 16% less energy and produces 9% less greenhouse gas emissions than other insulation material.

Renewable Energy

Wind turbines use a lightweight yet durable and aerodynamic material for their blades, ensuring that they spin at optimum speed generating the most electricity. Technicians are constantly experimenting with innovative new material to lighten the blades, with different variations of plastic creating the best effects.

Plastic currently accommodates solar cell renewable energy, through protecting panels and connecting and facilitating the internal parts. However researchers are developing a new technology where plastics can serve as the photovoltaic material inside the panels. The versatility of plastic would bring new and exciting options into the world of solar energy, with more flexible, lightweight and thin cells being potentially available to be printed onto a huge variety of surfaces.

Plastic has so much potential to help improve and change the world, and we are proud to be a part of the huge influence that is has, from our automotive projects to the intricate plastic medical parts we manufacture. Get in touch on +44 (0)1276 679394 or drop us an email at enquiries@tcb-arrow.co.uk to discuss what our team could do for you.

A Hundred Mile Bike Ride for Help the Heroes!

Mon, 03 Jul 2017 00:00:00 GMT

We are very proud to announce that 2 of our TCB-Arrow team have recently completed the Help the Heroes Dawn Raid bike ride! Leaving Horseguards parade at 3.30am, they cycled a total of 100 miles finishing on Southsea sea front. The route took in the breath-taking Box Hill and travelled through Aldershot and even down the runway at RAF Odiham.

Scott Rowell (Mouldshop Manager) and Nick Wright (Project Engineer) have raised £652 so far! This is a huge achievement for a very worthy cause, so well done to them both!

Our Large New Extension Has been Finished… And It Looks Great!

Fri, 16 Jun 2017 16:09:44 GMT

The TCB-Arrow team are excited that our new building extension has been completed! It is 5,000 sq.ft. and over 8m to eaves, making it a huge project which has been progressing from the beginning of the year.

With just the steel framework (below), we could start seeing the potential of the new space, and now that it is finished the extension is even more impressive than we could have hoped!

With a seamless transition between the original building and the extension, the result looks brilliant and will be a huge attribute to TCB-Arrow’s business development.

See below as our proud team stands by the workshop entrance as our drone takes aerial photos of the new building. We can’t wait to make the most of this space, so get in touch now to talk to our expert team on what we can do for you and your business on 01276 679394 or drop us an email at enquiries@tcb-arrow.co.uk .

How Are You Using Silicone in Everyday Life?

Fri, 26 May 2017 16:22:25 GMT

When most people think about the silicone items in their home, kitchen utensils such as cake cases, spatulas and non-stick products usually come to mind. However, there are a range of unusual and unexpected items in your house that are enhanced by including silicone, constantly improving our way of life. Here are a couple of ways silicone makes its way into your household:

It’s literally surrounding you. Silicone is used in building and construction, able to bond materials such as concrete, glass, granite, steel and plastics, enabling them to work better and last longer. These silicone sealants can absorb pressure and movement within engineering, allowing for more innovative architectural designs. It also helps protect materials and joints from moisture, heat, corrosion, sunlight, ultraviolet radiation, pollution and other chemicals.

You’re looking at or holding silicon right now. Silicone plays a huge part within the electronics industry. Silicon is a semi-conductor, meaning that it can conduct electricity only in certain conditions and acts as an insulator under others. These characteristics make it an ideal material for making transistors that amplify electrical signals. Coatings for electrical products, such as keypads, keyboards and copier rollers, as well as the hard coatings for computers, facsimile machines, telephones and home entertainment equipment are all made from silicone.

It’s not just silicon spatulas in your kitchen. Silicone is great for cooking utensils, as it has no odour and can can go from the freezer to the oven, microwave or dishwasher without affecting the quality of the product or the food, however it is used in other aspects of your kitchen too. Household cleaners and polishers often include silicon to enhance shine and spread easily.

Use a car to get to work every day? Silicone adhesives and coatings ensure that vehicle exteriors are more resistant to rain, wind, salt, abrasion, ultraviolet radiation and chemicals. Joints last longer and overall maintenance and repair is less costly. Silicone is used in a huge range of car parts, such as airbags, hydraulic bearings, ignition cables, shock absorbers and headlamps.

You might be wearing it! Silicone is used in a variety of make-ups, cleansers, shampoos and other personal care products to improve shine and texture.

At TCB-Arrow we have developed Liquid Silicone Rubber Moulding over the last 12 years. We aim to achieve the optimum tooling solution to meet our customer's criteria, so no matter for what industry the silicon will be used for, we know we can help. Give us a call on 01276 679394 or drop us an email at enquiries@tcb-arrow.co.uk to speak to one of our expert team.

We Have Joined the Blackwater Valley Countryside Trust!

Fri, 24 Mar 2017 15:10:19 GMT

We are excited to announce that TCB-Arrow have joined the Blackwater Valley Countryside Trust as an active corporate member. As a company, TCB-Arrow have always demonstrated a consciousness of the environment, both locally and globally. Through getting involved with the Countryside Trust, we have more opportunity to contribute to local environmental projects. As an organisation and individually, we are looking forward to participating in volunteer work parties and will keep you updated with any events that TCB-Arrow partake in.

TCB Continues Investment in Boosting Capacity & Efficiency

Wed, 15 Feb 2017 16:00:34 GMT

The New 130 Tonne Thermoplastic/LSR Injection Moulding Machine!

The TCB-Arrow team are delighted to have a new 130 tonne Thermoplastic/LSR Injection Moulding Machine delivered to their clean moulding workshop.

The machine is TCB-Arrow’s second Kraus Maffei 130 tonne machine and is capable of processing both Thermoplastic and Liquid Silicone Rubber (LSR). With a fully electric 3 axis beam robot and integrated conveyor, TCB-Arrow are excited to see the additional capacity in this area. “This further demonstrates our on-going commitment to investment and developing our Manufacturing capacity” quoted CEO, Murray Humphries.

At TCB-Arrow we pride ourselves on being specialists in the precision manufacture of Injection moulded parts from low to high volume production here in the UK. We provide solutions across all market sectors, so get in touch on 01276 679394 or drop us an email at enquiries@tcb-arrow.co.uk for more information.

Imaginative Ultimate Frisbees

Wed, 18 Jan 2017 00:00:00 GMT

We are excited to be working with a new Customer on a very original and fun project. For the last couple of months the TCB-Arrow team have been designing a new Thermoplastic Injection Moulding Tool for an In-Mould labelled Frisbee. The In-Mould labels will provide decorative graphics on the Frisbees from dinosaur scenes to this great pizza design! These labels are placed in the tool by a robot prior to injection moulding. This provides a high-gloss decorated surface that is very resistant to wear and peeling.

However it’s not all about appearance with these frisbees; an official ultimate frisbee disk should be between 175 and 200g and needs to have accuracy/balance in flight and the durability to survive impacts with most objects/surfaces. We are using an impact resistant grade of Polypropylene to provide this robustness, whilst ensuring that the frisbee looks cool and unique, perfect for a quick throw-around in the park to entire games of Ultimate Frisbee!

Another example where we have provided our Customer with an engineered and cost effective solution to satisfy market demand, so think of TCB-Arrow next time for any plastic or rubber solutions . We’d love to help your idea evolve, from concept through to high-volume manufacture. Get in touch on +44 (0)1276 679394 or drop us an email on enquiries@tcb-arrow.co.uk to answer any questions or queries, or fill out our quote request form for a complimentary quotation.

Do You Know these Everyday Items that are Injection Moulded?

Tue, 29 Nov 2016 16:35:12 GMT

Injection moulding is one of the most common manufacture methods used to create an array of everyday plastic objects. The versatility of injection moulding means it can be utilised to create intricate and tiny mechanical parts, to huge objects and casings.

Despite how complicated injection moulding plastic might sound to a consumer, it will have created a variety of apparently simple items found all around you. Here are a few examples:

1/ Smartphones

Are you looking at this on your smartphone right now? Although not all phones are made of plastic, most smartphones contain tiny and very intricate injection moulded plastic parts. Most electricals rely on injection moulded plastic to operate reliably, safely and consistently.

5/ Medical Equipment

Injection moulding is used to manufacture both single use disposable and reusable parts for the medical industry . At TCB-Arrow we manufacture medical parts in both Liquid Silicone Rubber (LSR) and Thermoplastics.

3/ Packaging

From fruit salad packaging and waterbottles, to cosmetics tubes and shampoo bottles, injection moulding is used to produce a huge range of food , hygiene and cosmetic packaging. We have produced an array of hygiene related products, such as fragrance air fresheners, soap dispenser and odour neutraliser devices.

2/ Cooking Utensils

Plastic bowls, plates, cups and eating utensils are generally injection moulded to create precise and durable kitchen equipment. Silicon spatulas, spoons and whisks are also injection moulded to create robust and heat-resistant cooking utensils.

5/ Automotives

When you are sitting in your car, you are surrounded by injection moulded parts. From the dashboard to the tiny buttons on your radio, most of the components surrounding you are injection moulded plastic. Not only that, but ignition leads, insulator boots and car number plate components are created through the same manufacturing process. Even the car bumper is probably injection moulded !

TCB-Arrow are specialists in the precision manufacture of Injection moulded parts from low to high volume production here in the UK. With a wealth of experience and expertise, we offer over-moulding and multi impression manufacture from very small to large size mouldings across the full range of Thermoplastics. Get in touch on 01276 679394 or drop us an email at enquiries@tcb-arrow.co.uk .

Escalating the future of the London Underground

Mon, 22 Aug 2016 00:00:00 GMT

In one of our most exciting projects to date, we have been working with Transport for London to improve the durability of their escalators.

In the past the escalator combs have been made of aluminium, but in partnership with TFL we have been developing a suitable durable plastic alternative. The result has been particularly successful and trails have been done on escalators throughout the capital. TFL are currently in the process of refurbishing 425 escalators across London’s Underground Stations.

New Facilities Enable Continuous Growth

Wed, 23 Mar 2016 00:00:00 GMT

TCB-Arrow has been under-going some exciting updates and we can’t wait to share the news with you. We have invested heavily in new space and machinery to ensure we are at the forefront of plastic innovation and can keep up with the ever increasing demand.

Our new machinery offers a 50% increase in our LSR silicone capacity, and we can now offer precision close loop injection moulding. For over 12 years we have been able to offer customers the flexibility of low volume prototypes to high volume technical components, with our LSR Moulding, and we are looking forward to being able to utilise our extra capacity.

Not only have we invested in new machines, we have also overhauled our warehouse, and now have a dedicated high bay section. With space for over 200 pallets, we have plenty of space to enable JIT manufacturing.

So we have more machines, more space, and fantastic transport links; our new warehouse provides the perfect base for future expansion and meeting current and rising demands.

New Negri Bossi Machines

Wed, 16 Dec 2015 00:00:00 GMT

'The 130 tonne and 330 tonne machines follow previous orders for Negri Bossi electric and hybrid models, and will also be fitted with three axis robots. ' Read the full article here .

Helping an inventor’s dreams come true

Fri, 18 Sep 2015 00:00:00 GMT

TCB-Arrow were approached by Melissa Edmunds with the concept of a cover to stop drinks spilling. Trademarked Safesip , this cover would be for the childcare, elderly, and disabled markets, so it had to be versatile for different types of cups and glasses. To do this, we designed and manufactured a liquid silicone injection tool to meet Melissa’s criteria and create a successful product.

Made from food grade silicone, the Safesip is 100% BPA free as well as being dishwasher and microwave safe. Its clever design fits onto virtually any glass, mug, cup, or can, making drinking with dignity easier than ever.

The hard work has certainly paid off, with Melissa and the Safesip winning multiple awards. We are so proud that it is becoming a household brand and is rated 9.5 out of 10 on Trust Pilot.