Built for the cleanroom.
Fixtures, nests and process tooling for cleanroom assembly, plus semi-automatic process stations and full production lines, taken from concept design through to manufacture.
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Automation concepts for medical and pharma lines.
A selection from our machine concepts. Each was delivered as a layout, 3D model, process description and budget, so the client could make a go or no-go decision before committing to a build.
Concept stage: 3D models and process layouts, not installed equipment.
Pharma · concept
Fig. 01
Front elevation
Plan viewVial filling and capping machine
A concept for filling and capping ready-to-use vials under an open-RABS enclosure. Vials index through the fill and cap stations on a starwheel, with the format parts laid out so a size changeover is a tooling swap rather than a rebuild. The concept covers the enclosure, the indexing layout and the operator access positions, and was modelled far enough to size the frame and check reach and guarding before any costing.
RTU vials · Open RABS enclosure · Starwheel indexing · Format-part changeover
Medical · concept
Fig. 02
Robotic glue dispensing station
A dispensing concept built around a SCARA robot and multi-camera vision, with parts carried through on a linear-motor track. Vision locates each part before the bead is laid, so the dispense path follows the part rather than assuming it landed in the same place every cycle. The layout was drawn to keep the dispense head, the cameras and the operator load point all reachable without crossing the robot envelope.
SCARA robot · Multi-camera vision · Linear-motor track · Path correction from vision
Medical · concept
Fig. 03
Compact robot dispensing cell
A self-contained six-axis dispensing cell sized to drop into an existing line without rearranging it. The HMI and guarding are integrated into the frame rather than bolted on afterwards, which keeps the footprint tight and leaves one clear operator face. Drawn as a concept to establish the envelope, the access positions and the budget before detailed design.
6-axis robot · Integrated HMI · Full guarding · Single operator face
Recent medical engineering projects.
A selection of fixture, tooling, and mold projects delivered for medical and pharmaceutical manufacturers.
Built · in use
Fig. 04
3D CAD model
On the floorLight-block enclosure frame
A modular aluminium-profile frame with opaque panels that shields a vision station from ambient light, so inspection results stay repeatable regardless of what the room lighting is doing. The frame is built from standard profile, so panels can be swapped or the aperture resized without remaking the structure, and it was designed around the existing bench footprint to avoid relocating the station.
Aluminium profile · Opaque light-block panels · Bench-footprint fit · Designed, built and in use
Assembly fixture
Fig. 05
Two-cavity component fixture
A precision dual-cavity assembly fixture designed for repeatable positioning of small medical components during manual assembly operations. Integrated locator pins ensure consistent orientation and reduce operator variability. Machined from aluminium with hard-anodised finish for cleanroom compatibility.
2-cavity · Aluminium · ESD-safe · ISO Class 7 compatible
Thermoform mold
Fig. 06
8-cavity medical tray mold
Custom thermoform mold tool designed for the high-volume production of medical-grade PETG packaging trays. The 8-cavity layout maximises throughput per cycle while maintaining tight dimensional tolerances required for sterile packaging applications. Designed with optimised drainage geometry and uniform wall thickness for consistent forming quality.
8 cavities · PETG compatible · EU 10/2011 · Drainable geometry
Reverse engineering
Fig. 07
Stainless steel filling funnel
Originally manufactured in plastic, the existing filling funnel suffered from low mechanical strength and repeated failure under operational stress. BioFlex redesigned and manufactured the component in stainless steel, improving durability, hygiene compliance, and resistance to wear. The redesigned funnel maintains the original geometry while delivering significantly extended service life.
Stainless steel · Reverse engineered · Hygienic finish · Extended service life
Services
- Assembly jigs and fixtures
- Manual, semi-automated, and fully automated.
- Test and inspection fixtures
- For in-process and end-of-line verification.
- Ergonomic ESD-safe workbenches
- Designed for cleanroom integration.
- NPI and R&D phase concept tooling
- Rapid iteration, weeks not quarters.
- Process design and line flow
- Fixture-to-fixture sequencing, ergonomic layout.
- Fume extraction (LEV)
- For soldering, bonding, and adhesive operations.
- Cleanroom-compatible storage
- Shelving, racking, kanban systems.
- Reverse engineering of legacy fixtures
- Modernisation and like-for-like replacement.
Compliance & standards
BioFlex designs to cleanroom constraints: ISO Class 7 and 8 compatible materials, ESD-safe surfaces, low-particulate finishes, and cleanability for CIP and manual cleaning. We work to your QMS and documentation standards and provide full material traceability.
Got a jig, fixture, or tooling challenge?
Send us your problem. We'll come back with a scoping outline within 5 business days.