The benefits of advanced measurement technology for efficiency, data integrity, process validation, and zero-defect production in medical device manufacturing

Kistler Instrument Corporation, a global leader in test and measurement technology, will present its broad MedTech product portfolio at MD&M Midwest in Minneapolis from October 21st to 22nd 2025, to address the rising quality demands and sustainability requirements in the MedTech industry. Visitors to booth #2513 in hall B-E will discover how advanced measurement technology provides transparency and control that empowers manufacturers to achieve their vision of zero-defect production with systems compliant to medical standards.

Precision and speed for next-generation MedTech assembly with NCFQ 2166A
The latest NCFQ 2166A sets new standards for the precision and speed of joining systems, for example in the assembly of insulin pens or auto-injectors. It combines the rapid response of linear direct drives with the accuracy of piezoelectric sensors. The compact system can accelerate up to 50 m/s² and reaches speeds of up to 5 m/s, making it ideal for highly dynamic joining applications with small forces of up to 500 N.

This unique capability significantly improves process reliability and control. It ensures that critical assembly steps remain stable and traceable, even during rapid movements and high accelerations. In MedTech manufacturing, where even the slightest deviation can affect device performance and patient safety, this level of precision gives manufacturers a clear advantage by providing consistent quality, reliable validation, and robust, future-proof production processes. When integrated with Kistler's maXYmos NC process monitoring system and equipped with optional acceleration sensors and an ICAM-B industrial charge amplifier, it enables automatic acceleration compensation and precise measurement of joining forces.

Meeting MedTech demands with intelligent process monitoring
Another challenge is the production of injection-molded components with extremely tight tolerance and absolute reliability while minimizing waste and keeping costs under control. Variations in material batches or fluctuating process conditions can quickly compromise quality and efficiency. By creating a signature curve analysis to each validated process and real-time controls, Kistler systems will provide the understanding for our customers' own innovation.

ComoNeo 7.0 from Kistler addresses these challenges with its state-of-the-art process monitoring capabilities. Its new Multiflow 2.0 algorithm uses self-learning control to automatically balance multi-cavity filling, ensuring consistent quality with every cycle. Melt cushion monitoring provides additional support for precise adjustments, helping to prevent defects and optimize material use. With AI-driven quality predictions from ComoNeo Predict and real-time control through Multiflow, the system ensures continuous compliance with strict MedTech requirements, reduces scrap, and minimizes the need for downstream inspections, bringing production closer to the goal of zero-defect manufacturing.

AkvisIO 7.0: centralized data management for manufacturers
As injection molding becomes more complex, the ability to collect, consolidate, and analyze data from various sources becomes critical, especially in the highly regulated MedTech sector. With its latest release, AkvisIO 7.0 has become a comprehensive platform for process data management, offering users a solution for managing their data that is both user-friendly and efficient. The new Euromap 77 interfaces enable seamless connectivity to additional machines and monitoring systems, including Kistler's ComoNeo. Additional functions, such as multi-component visualization and long-term histogram trend analysis, provide users with precise process overviews and AkvisIO the single source of truth for reliable production data.

Smarter monitoring for complex processes
The new maXYmos BL 5867C improves quality assurance in automated joining and pressing applications with faster evaluations, intuitive operation, and extended connectivity. Its larger touchscreen enhances usability, while USB support simplifies data handling and enables barcode integration. New licenses add advanced features, including user-group access protection, sequencer mode, and OPC UA for IIoT environments. With up to ten evaluations per second and seamless integration via EtherCAT, PROFINET, or EtherNet/IP, the system reliably monitors across MedTech, automotive, and electronics production processes.

Stronger U.S. presence: Kistler strengthens its West Coast hub in Irvine, CA
Kistler's Irvine office provides direct access to Kistler's sensors and measurement technologies, along with practical application support for customers in the MedTech, aerospace, automotive, infrastructure monitoring, and traffic industries. By combining customer support, educational collaboration, and talent development, Kistler is promoting innovation, knowledge sharing, and operational excellence throughout the region.