Ypsomed is making a major investment in a new tool manufacturing facility in Solothurn, Switzerland. This expansion will double the company’s production of high-precision injection moulding tools, which are essential to the manufacture of its self-injection devices. The new site mirrors the company’s existing operations in Burgdorf, with near-identical machinery and processes, ensuring seamless integration and consistency across both locations while boosting capacity.
State-of-the-art machinery and technology
The Solothurn facility is set to feature advanced machinery, including 5-axis milling machines, grinding machines, and electrical discharge machining (EDM) systems, such as wire and sinker EDM. Michael Maurer, Project Manager Tool Manufacturing, emphasized that these machines are critical for achieving the precision and surface quality required for Ypsomed’s injection moulding tools. “We are investing in a completely new tool manufacturing facility to double the output we currently generate at our headquarters in Burgdorf,” Maurer stated.
A significant portion of the investment is dedicated to introducing a flexible manufacturing system (FMS), which enhances automation and adaptability in handling complex machining tasks. Elias Wermuth, Manager Tool Manufacturing, noted that this setup enables Ypsomed to replicate the high precision standards established at the Burgdorf site.
Tool manufacturing: a core component of pen and autoinjector production
Tool manufacturing is central to Ypsomed’s ability to produce self-injection devices like pens and autoinjectors. Wermuth explained, “We essentially are the internal supplier of injection molding tools for Ypsomed’s pen production. Without our injection molding tools, there would be no pens or autoinjectors.” The precision and complexity required in creating these tools are fundamental to the entire manufacturing process. For instance, a mid-sized mold takes approximately 1,800 work hours to complete, reflecting the level of expertise and detail involved.
Ypsomed emphasizes precision throughout the tool manufacturing process. The tools produced in Solothurn and Burgdorf are designed to operate within extremely tight tolerances—often as small as 3 microns—to ensure consistent performance over millions of production cycles. Once completed, each tool undergoes rigorous testing, including extensive cycle runs, to confirm it meets Ypsomed’s stringent standards for durability and performance. Maurer explained, “Once the tools pass our quality checks, they are cleared for production. Each tool must typically run five to ten million cycles during the production process.”
Developing skilled workers through apprenticeships
Recognizing that advanced technology alone is insufficient, Ypsomed is committed to developing a highly skilled workforce. Wermuth highlighted the crucial role of apprentices in the tool manufacturing division, stating, “We consciously maintain a high proportion of apprentices to strategically develop our future specialists.” The company’s apprenticeship programs ensure that trainees gain hands-on experience with advanced machinery, such as 5-axis milling machines, from their third year of training.
The investment in Solothurn underscores Ypsomed’s commitment to nurturing local talent and developing the skilled workforce necessary for success in high-precision manufacturing.
Strengthening Switzerland’s manufacturing base
Ypsomed’s investment in Solothurn not only strengthens its production capacity but also reinforces its commitment to Swiss manufacturing. The new facility is expected to create jobs and expand the company’s apprenticeship programs, thereby supporting the long-term growth of Switzerland’s high-end manufacturing sector. Maurer remarked, “This investment will not only establish one of the most modern tool and mold-making operations, but it will also create new full-time positions and an integrated apprenticeship program in Solothurn.”
Maximising operational efficiency and workforce productivity
Ypsomed’s investment in Solothurn goes beyond expanding capacity; it ensures greater operational efficiency across both of its manufacturing sites. By replicating the Burgdorf facility, Ypsomed has standardised its machinery and systems, enabling employees to quickly adapt and become productive, regardless of their location. This integration allows for consistency in precision and quality while streamlining training processes.
This blog post is based on an interview originally published in Schweizer Maschinenmarkt. You can read the full interview in German here.
Glossary of terms
5-Axis milling machines:
Milling machines that move cutting tools or parts along five different axes. This allows for extremely precise and complex machining, enabling the production of parts with intricate geometries, which are often required in the manufacturing of self-injection devices.
Grinding machines:
Machines used to finish surfaces by removing small amounts of material through abrasion. Grinding is essential for achieving the desired surface finish and high precision in tool manufacturing.
Electrical Discharge Machining (EDM):
A machining process where electrical sparks are used to shape hard materials by eroding them. This method is ideal for creating detailed and complex shapes in materials that are difficult to machine using traditional methods.
Wire EDM:
A type of EDM that uses a thin wire to cut through metal with high precision. It is particularly useful for creating intricate shapes and fine profiles in tool manufacturing.
Sinker EDM:
Another form of EDM that uses a shaped electrode, "sinking" it into the material to erode and create cavities or complex shapes. This process is often used for creating moulds and dies with deep, detailed features.
Injection moulding tools (moulds):
Precision-made tools used in the injection moulding process, where molten material (such as bio-based plastic) is injected into a mould to form the desired part. These tools are essential in manufacturing medical devices like self-injection pens and autoinjectors.
Flexible Manufacturing System (FMS):
A production system that allows for automation and adaptability, enabling manufacturers to switch between different tasks or products efficiently. FMS is key for handling complex machining tasks while maintaining high precision and productivity.
