Hello Franck, could you briefly introduce yourself?

With a CAP/BEP in mechanics, I began my career as a precision tool mechanic. I joined Manuplast nearly 34 years ago. I initially managed the mechanical workshop before taking charge of both the injection and mechanical operations of the production site for about twenty years.

Today, as Production Manager, I work closely with the design office and our clients, handling quotations, commercial proposals, and the overall coordination of projects.

Franck, can you explain what PEEK and PPSU are?

PEEK and PPSU are high-performance engineering plastics positioned at the premium end of the market. Their cost is higher than that of standard polymers—particularly PEEK—but their exceptional properties fully justify the investment. Today, they represent excellent alternatives to metal alloys for a wide range of mechanical components.

These materials stand out for their light weight, exceptional mechanical strength, and high chemical stability. They can be injected using multi-cavity molds while delivering a robustness comparable to steel. Another key advantage is their excellent resistance to chemical agents, making them perfectly suited for demanding environments such as medical and food-processing applications.

PEEK

PEEK is a semi-crystalline polymer known for its outstanding performance. It offers extremely high heat resistance—up to 600 °C—an exceptional level for a plastic material. This thermal stability, combined with excellent chemical resistance, makes it a material of choice for demanding sectors such as medical devices, automotive, oil, and gas. Its light weight is another major advantage: PEEK enables significant weight reduction compared to steel, without compromising strength or durability.

At Manuplast, we have been working with PEEK since the early 2000s. Our expertise truly advanced when we began supporting Eversys, a machine manufacturer founded in 2009. Through close collaboration with their engineering department, we refined our processes and developed a recognised industrial know-how in mastering this material.

The choice of PEEK for coffee machine components quickly became the obvious solution: these systems must withstand extreme and instantaneous temperature variations, and PEEK provides the best mechanical and thermal performance under such conditions. The goal is to replace as many metal parts as possible with PEEK, significantly reducing the overall weight of the machines while ensuring long-term durability.

PEEK is also widely used in other advanced industries, particularly in the pharmaceutical and medical sectors. For example, it is used in the manufacturing of implantable components designed to remain inside the human body for a lifetime.

PPSU

PPSU is a material that shares many similarities with PEEK, but it has a much higher viscosity. In practical terms, this means it is thicker and more difficult to inject into thin-walled parts. This characteristic makes it more demanding to process, yet it still offers excellent mechanical and thermal properties. In addition, as an amorphous thermoplastic, PPSU can be injected to produce transparent components.

PPSU is particularly well suited for manufacturing parts used in sterilisation equipment, especially those exposed to temperatures between 100 °C and 140 °C, such as in autoclaves. It withstands these extreme conditions very well while ensuring long-term stability and performance.

Its cost is lower than that of PEEK, making it an attractive alternative when geometric constraints are less demanding. We have been working with PPSU for around fifteen years and have developed genuine expertise in injecting this challenging material, fully capable of meeting the requirements of the medical, pharmaceutical, and industrial sectors.

How are PEEK and PPSU injected in molding presses? Are the same machines used as for other plastic materials?

The presses used to inject PEEK and PPSU are the same as those used for other plastics, but the settings and operating conditions are far more demanding. The process still relies on a screw system and electric heating elements to melt and transform the material, but the parameters must be carefully adjusted to match the specific characteristics of these high-performance polymers.

Both materials require presses capable of reaching very high temperatures, up to 450 °C. The molds must also be heated to around 200 °C, compared with only 20 to 60 °C for more common plastics such as ABS or polypropylene.

These extreme temperatures require powerful electric heaters, oil or water temperature controllers, and tooling materials specifically designed to withstand such thermal constraints. Depending on the part to be produced, it is also essential to select the most suitable grade of PEEK, as viscosity varies from one grade to another. By choosing the right PEEK, it becomes possible to manufacture highly precise components with thin walls while maintaining excellent mechanical performance.

With PPSU, depending on the desired part geometry and the possible tooling adjustments, the final result remains perfectly suited for applications requiring high resistance and thermal stability.

Are there specific processes involved when working with these types of materials?

We use the same type of mold as for most other plastic materials, but several design parameters must be adapted. Mold temperature control, for example, is very different from that of a standard mold.

When working with PEEK or PPSU, experience plays a fundamental role. It is through practice, testing, and problem-solving that process settings can be refined and the transformation of these technical polymers can be mastered. At Manuplast, this expertise has been built over many years and many projects, becoming a true industrial know-how.

Today, our teams fully master the design of tooling adapted to these materials, ensuring homogeneous mold heating at around 200 °C and stable injection conditions. Because PEEK is a semi-crystalline material, it requires a heated mold to guarantee the quality and integrity of the final part.

Our experience also allows us to optimise material flow within the cavities by adjusting the geometry of the feed channels or the size of the injection gates, ensuring perfect filling regardless of the part’s complexity.

What makes Manuplast unique within the Mora Group?

Manuplast’s strength lies in its ability to manage the entire process, from mold design to part injection. The company operates a design office, a mechanical workshop, and an injection workshop, which gives it exceptional responsiveness. Whenever fine-tuning or adjustments are required, the mold can be dismantled, modified, and returned to production all within the same day.

This agility also relies on the versatility of our teams. At Manuplast, employees are able to work across different specialties: a process technician can suggest a mechanical improvement, while a mechanic may identify an optimisation in the injection process. This complementarity creates real synergy between teams and strengthens the overall efficiency of production.

Knowledge sharing within the Mora Group has also played a key role. The multidisciplinary expertise across the group has significantly expanded our skills, while Mora’s investment capacity enables us to modernise our equipment—such as integrating new electric presses and a new cooling system.

Manuplast is also equipped to meet the requirements of controlled environments. We can process PEEK and PPSU in compliance with ISO 8 standards, using laminar-flow systems that ensure optimal air filtration.Manuplast assure sur place différentes opérations de finition et d’intégration, comme la tampographie, les montages, les assemblages ou encore le conditionnement. Ces prestations sont généralement réalisées sur de petites séries, ce qui nous permet d’offrir une grande flexibilité et un contrôle qualité renforcé.

On-site, we also handle various finishing and integration operations, such as pad printing, assembly, sub-assembly, and packaging. These services are most often carried out on small production runs, allowing us to offer great flexibility and reinforced quality control.

We also maintain a close collaboration with the research and innovation ecosystem and support many start-ups in their early development stages. These young companies often require small batches to validate their concepts, and this is precisely one of Manuplast’s strengths: the ability to deliver technical, low-volume parts with the same level of quality as large-scale production.

Through its various subsidiaries— including Manuplast in Switzerland—Mora Group has established itself as a leading reference in the transformation of high-performance technical plastics. The combined expertise of its teams allows the group to master complex materials such as PEEK and PPSU.

This mastery is built on comprehensive industrial know-how: mold design and manufacturing, injection molding, assembly, finishing, and quality control. This vertical integration gives Mora Group exceptional agility, enabling it to handle both small-batch projects for research, prototyping, or start-ups and large-scale production runs.

With extensive experience and a deep understanding of high-temperature injection processes, Mora Group supports its clients in highly demanding markets such as food processing, pharmaceuticals, and medical technology.

Whether the parts are intended for sterile environments, extreme thermal conditions, or stringent regulatory requirements, Mora delivers reliable, high-performance solutions tailored to every industrial need.

I’m Christophe Basset, Industrial Methods Manager at Mora Group since 2006. My role is to design, define, and implement all the processes and industrial resources required for the production of injected parts — except for the molds. I oversee the definition of production lines, injection presses, and associated robots, as well as the creation of controlled atmosphere areas (ISO 7 and ISO 8). I’m also involved in integrating post-injection assembly and inspection machines. My mission is to support Mora Group in developing and implementing automation and robotics solutions tailored to our clients’ needs and the demands of their markets.

Christophe, can you explain the difference between robotization and automation? What does each term actually mean?

We can distinguish between automation and robotization. Automation often involves robotics, but not always. Some steps, such as packaging, can be fully automated without any direct use of robots.

In our field of plastic injection molding, the first step after injection is to unload the molded parts. This can, of course, be done using dedicated robots, but also through automatic systems that don’t rely on robotics. For example, we use counting and packaging systems combined with conveyors, which allow us to efficiently manage the continuous production flow.

What are the concrete benefits of automation in the plastic injection molding industry?

What types of robots are used at Mora Group, and what are their main functions?

Coming back to robotics, we use several different types of robots:

• So-called “cartesian” robots

Particularly for productions intended for the automotive sector. These robots operate on three axes (X, Y, and Z), similar to a mathematical coordinate system, and are the most common type used in the plastics industry. Their arm moves up and down along the vertical axis, while a horizontal beam allows them to travel and perform part pick-and-place operations.

Although this system can be bulky, it allows for extended reach and is perfectly suited to managing multiple part references. Another advantage is its ability to handle heavy loads.

• High-speed side-entry robots

These robots are used for productions with very short cycle times. Their purpose is to minimize the robot’s intervention time inside the mold and avoid impacting the overall injection cycle duration.

• 6-axis robots

In France, Mora Group primarily deploys 6-axis robots, especially for medical applications. These robots offer multiple advantages:

• Their compact design makes them particularly well-suited for cleanrooms, where every cubic meter must be optimized to minimize the air volume handled by filtration systems.

• They also stand out for their low particle emission and ease of cleaning. Some models used by Mora Group can operate in environments up to ISO Class 5, ensuring full compliance with the stringent standards of the medical and pharmaceutical industries.

• Most importantly, they provide greater freedom of movement, making them ideal for post-injection operations.

Today, the French site in Chambost-Allières is equipped with 6-axis robots used for part unloading as well as specific tasks such as vision-based quality control, packaging, and pad printing. This versatility enables cleanroom integration of finishing and customization stages while maintaining the highest standards of cleanliness and traceability.

What criteria guide your choices between the different types of robots and automation solutions?

The systems implemented to optimize existing production lines are primarily driven by productivity gains, balanced against the cost of the required investment.

When it comes to new projects, installations are always designed around the specific characteristics of each product. The choice depends on multiple parameters such as the associated machine, type of production, cycle time, number of part references to manage, and the operations to be performed on the product (assembly, sorting, inspection, etc.). Robots provide the flexibility needed to adapt to these requirements and ensure solutions that are perfectly aligned with each product’s specifications.

For each new project, and according to the specific needs of the client and the product, Mora Group develops complete automatic or semi-automatic assembly lines, as well as special-purpose machines — particularly for assembling components for the automotive industry at our Portuguese and Romanian sites. These dedicated systems ensure both assembly reliability and strict adherence to the cycle times and cost requirements demanded by the sector.

Mora Group continuously upgrades its robot fleet and automated lines to meet client needs and adapt to upcoming projects, always with a focus on staying at the forefront of existing technologies.

The company remains attentive to emerging innovations, particularly artificial intelligence, which is already integrated into our camera-based inspection systems. These systems automatically verify part quality at the end of the injection process, offering unmatched reliability and speed. AI enhances inspection accuracy, reduces human error, and ensures consistent batch compliance.

Data processing software applied to injection molding already enables continuous self-diagnosis of machines. These advancements are paving the way for more predictive industrial processes — capable of anticipating deviations and adjusting production parameters in real time.

Artificial intelligence already plays, and will increasingly play, a key role in automation — and robots will undoubtedly be part of that evolution.

To be continued…

I’m Vincent Collard, Technical Director at MORA Group and a mechanical engineer graduated from UTC Compiègne.
After an initial experience in subcontracting, I spent 15 years in the automotive industry, designing engine sensors and mechatronic systems for manufacturers such as PSA, Renault, BMW, and Ford. I led teams and managed projects from design through to production launch.
I then took on new challenges in the renewable energy sector, overseeing large-scale projects for EDF and Aéroports de Paris.
Today, I bring this expertise to MORA’s clients, supporting them in their most complex projects with precision and high standards.

Vincent, could you explain what laser welding of microfluidic chips made of COC involves?

To begin with, COC (Cyclic Olefin Copolymer) is a plastic material particularly well-suited for microfluidic devices. It stands out for its excellent optical transparency, biocompatibility, and low chemical leachability. These properties make it a credible and increasingly common alternative to glass, which has historically been used for such applications. With performance characteristics similar to glass, COC is becoming a strategic choice for the design of microfluidic chips.

What is a microfluidic chip, and what are its main applications?

Microfluidic chips are small devices used to handle very small volumes of liquids. They are at the core of numerous applications in medical diagnostics and biology. Today, this technology is experiencing significant growth, particularly in the areas of screening and analytical testing.

Microfluidic chips operate somewhat like the COVID test cassettes that most people are familiar with. The chips are inserted into diagnostic devices, just like the COVID cassettes, to deliver fast and accurate analysis results. The tested samples typically consist of drops of blood or other bodily fluids, and the results indicate the presence or absence of specific pathogens.

At Mora, we are directly involved in the manufacturing of these microfluidic chips. Our clients are primarily the manufacturers of diagnostic devices, with whom we collaborate to produce microfluidic chips tailored to meet strict technical and medical requirements.

These chips are integrated into diagnostic systems that use a wide range of technologies, depending on the specific application — including infrared detection, ultrasound, or genetic analysis. Their strength lies in their ability to detect elements at the molecular level using very small sample volumes: a single drop of blood, sweat, or another bodily fluid is often enough.

The applications are numerous: disease detection, genetic screening, biomarker research, as well as quality control in the food industry—such as detecting traces of gluten. This wide range of uses makes microfluidic chips a key enabler in the advancement of bioproduction and personalized diagnostics.

The fundamental principle of microfluidics is based on manipulating extremely small amounts of liquid through networks of microchannels. When a sample—such as a drop of blood—enters a microfluidic chip, it is divided into a multitude of micro-droplets, sometimes numbering in the tens of thousands. Each droplet can then be analyzed individually. This process enables highly precise analyses, often supported by statistical models, to confirm or rule out the presence of a biomarker, disease, or specific agent.

There is a wide variety of microfluidic chips, with different architectures depending on their intended use. However, the principle of sample fragmentation and multipoint analysis remains central to many applications.

What types of microfluidic chips does MORA Group manufacture?

The microfluidic chips we work on incorporate complex networks of microchannels, which are essential for guiding the liquid sample, fragmenting it into micro-droplets, or directing it toward a targeted analysis zone.

These components require an extremely high level of precision. Some applications demand the fabrication of channels as small as 20 to 40 microns, with dimensional tolerances within just a few microns. This degree of accuracy is what enables diagnostic machines to deliver reliable results.

We have notably developed microfluidic chips for the IPGG (Pierre-Gilles de Gennes Institute), a leading research organization in France specializing in microfluidics. The institute collaborates with a wide range of partners across various application fields. Our work has included not only the manufacturing of high-precision microfluidic chips but also the laser welding assembly of components.

Qu’est ce que l’IPGG 

IPGG is a French interdisciplinary research center specialized in microfluidics and nanofluidics. It is affiliated with PSL University and brings together teams from ESPCI, ENS, Institut Curie, and Chimie ParisTech. IPGG combines both fundamental and applied research, relying on a multidisciplinary team of physicists, biologists, chemists, and engineers to develop new microfluidic technologies

Indeed, in all applications, microfluidic chips must be hermetically sealed without obstructing the channels or compromising their functionality.

Pourquoi souder une puce microfluidique ?

To begin with, laser welding technology is not new; it was already in use more than twenty years ago, particularly in the automotive industry for assembling sensors. Even then, it proved to be an effective alternative to other assembly methods, including in complex and automated architectures.

When it comes to microfluidic chips, however, the level of precision required changes drastically. Accuracy becomes critical. The components are smaller, the tolerances much tighter, and every weld must be perfectly controlled to ensure the sealing of microchannels and the reliability of diagnostic performance.
The challenge, in this context, isn’t the welding technology itself—but rather adapting it to micro-scale assemblies, where the slightest deviation can compromise the system’s functionality.

The manufacturing of a microfluidic chip typically begins with the injection molding of a base component, which serves as the main support. This is where the microchannels are formed with the high level of precision needed for the system to function correctly.

But the molded part alone is not enough! To become operational, it must be sealed. A flat film is added on top as a cover to close off the microchannels. The goal is to achieve a perfectly airtight assembly that allows for controlled fluid circulation. This step requires a welding or bonding process that can join the two components without deforming the delicate structures of the molded part.

Why use laser welding for this type of product?

Until a few years ago, microfluidic chips were mainly assembled using chemical processes, particularly adhesive bonding. These techniques had several drawbacks: long processing times, complexity in industrial-scale production, and—most importantly—the use of potentially harmful chemicals. This poses a significant issue in medical environments, where material purity is critical.

In this context, Mora made the strategic decision to offer laser welding as an assembly solution. This technology offers several advantages: it is fast, clean, and easily scalable for industrial production, and it does not introduce any foreign materials. Only the properties of the original plastic components are utilized. This last point is particularly important for diagnostic and biomedical applications, where any external contamination must be avoided. Laser welding has therefore established itself as a reliable, clean solution that meets the strict requirements of the sector.

At Mora, we validated this approach through a Proof of Concept (POC), which allowed us to demonstrate that laser welding can achieve all three critical objectives: perfect sealing in highly targeted areas, reliable mechanical strength, and—most importantly—strict compliance with the micro-precision required by the chip’s structure.

It’s a true technical challenge, as the welding must be done without obstructing the surrounding microchannels. Some areas of the part feature channels as small as 20 microns in height, with tolerances of just a few microns in both width and depth. The welding process must therefore be extremely localized, precisely controlled, and highly repeatable.

Another major advantage of this process is the ability to integrate inline camera-based inspection, enabling automatic quality control of welds in critical areas.

Today, we are already using highly specialized laser welding machines. However, as volumes increase, our goal is to integrate them into fully automated production lines to ensure scalability, repeatability, and productivity.

What are the different types of laser welding used for this kind of application?

In the field of laser welding for assembly, three main technologies stand out, each suited to specific needs depending on the geometry of the parts and the sensitivity of the areas that must be preserved:

• Contour laser welding: In this approach, the laser beam follows a precise path around the weld area. The laser moves along the microchannels, following a defined trajectory. This method is well-suited for complex shapes and highly localized welds.
• Mask-based laser welding: This technique involves projecting a laser beam across the entire surface, while protecting sensitive zones with a copper mask. The mask shields areas such as fluidic channels from exposure to heat. The laser sweeps the surface, heating only the unmasked regions. This method is particularly suitable for assemblies that require strict preservation of functional areas..
• Hybrid technology: There are also combined processes that leverage the advantages of both contour and mask-based welding, offering greater flexibility and precision depending on the application.

To optimize the laser welding process, Mora chose to use mask-based assembly.

Could you tell us a bit more about mask-based laser welding?

To ensure a reliable and repeatable assembly, Mora has implemented a tightly controlled laser welding process. It all begins with precision fixturing: the molded component is first positioned on a dedicated support, then the sealing film is placed on top. This step is critical, as it requires strict flatness tolerances.

To meet these demanding requirements, Mora developed a dedicated film-guiding system to ensure perfect flatness of the entire assembly prior to welding. A glass plate is then applied to apply uniform pressure across the stack. The copper mask, which defines the weld zones, is integrated into this glass plate.
The laser scan is carried out with extreme precision: only the areas exposed by the mask are welded. To achieve this, the mask itself must be machined with even greater precision than the final part, as beam diffraction can occur through the thickness of the mask—requiring exceptionally high-quality machining.

This level of precision led Mora to collaborate with specialized partners for both mask fabrication and laser welding. Thanks to this rigorous approach, the results achieved fully met expectations in terms of accuracy, with tolerances kept within just a few microns.

Today, the laser welding assembly process developed by Mora is capable of meeting a wide range of industrial needs—particularly in the demanding fields of medical diagnostics and microfluidics. Few players have mastered these technologies with such precision, giving Mora a unique position in this high-precision market.

Are there many of you who have mastered this technology?

Not really! That’s precisely why Mora is actively involved in a consortium of French stakeholders united around a common goal: to revive and structure a true microfluidics industrial sector in France. While our country has long been at the forefront of research in this field, that leadership hasn’t always translated into local industrialization.

The technology exists, the expertise is there—but what needs to be strengthened now is the production ecosystem. The COVID-19 pandemic and the rise of genetic testing have acted as catalysts for awareness, highlighting the strategic importance of these technologies for both public health and industrial sovereignty.

At Mora, this ambition is reflected in close partnerships with research organizations such as the Pierre-Gilles de Gennes Institute, in collaboration with prestigious institutions like the Institut Curie. This dialogue between fundamental research and industrial know-how is key to developing concrete, locally manufactured solutions that meet today’s medical and technological challenges.

How do you see the future of this technology that Mora has mastered so well?

Over the past two years, the field of microfluidics has experienced real momentum. Whether in research institutions or, more recently, in the industrial sector, initiatives are multiplying—driven by healthcare, innovation, and sovereignty challenges. The ambition is clear: to position France as a major player in this technology, building on its internationally recognized excellence in medical research.

MORA Group is fully committed to this dynamic—both in laser welding for assembly and in plastic injection molding. The upcoming projects already present new, even more demanding technical constraints that will require us to explore advanced injection technologies.

Each new development is a true challenge, especially in terms of precision, but it’s also what fuels our passion and commitment. Microfluidics is a field where every detail matters—and it is precisely in this level of rigor that MORA Group finds its purpose and legitimacy.

I’m Vincent Collard, Technical Director of the MORA Group and a mechanical engineer with a degree from UTC Compiègne.
After starting my career in subcontracting, I spent 15 years in the automotive industry, where I developed engine sensors and mechatronic systems for major manufacturers such as PSA, Renault, BMW and Ford.
There I managed teams and supervised the entire project lifecycle, from design to production.
I then took on new challenges as a key account project manager in the solar power plant sector, managing major projects for EDF and Aéroports de Paris.

Today, thanks to this experience in managing complex projects, I’m able to support MORA’s clients with rigour and expertise.

At Mora, we have set up a specific organisation to manage all this seamlessly. We identify critical dimensions at an early stage in the development process and monitor the continuity of measurements between development and production, to avoid any measurement discrepancies or biases.

We pay particular attention not only to the measurement of parts, but also to the quality of the measuring equipment itself. The equipment must be suitable and accurate, and the results must be repeatable and reproducible – in other words, reliable, whatever the operator.

To achieve this, we systematically carry out R&R (Repeatability and Reproducibility) studies on the measuring equipment used for these critical dimensions. In some cases, our customers also carry out their own checks upon receipt.

There are two possible situations:

Correlation of measurements: we compare our results with theirs, looking for any bias. Ideally, this would involve using the same equipment and the same fixtures. We sometimes suggest developing duplicate set-ups to limit differences, but this isn’t always feasible because our customers don’t always have the same machines as we do.

Full delegation of measurement: some customers prefer to delegate measurement to us and validate our metrology reports, capability studies and certificates. In this case, Mora is responsible for batch release.

It’s not just the fact of doing metrology that’s an asset. It’s the internal organisation dedicated to dealing with it that makes all the difference at Mora Group.
When I took over as Technical Director in 2016, quality was not under my authority. This could have led to some cumbersome exchanges.
At the time, the Quality department provided the measurement reports, without being involved in the decision whether or not to rework the moulds. This meant longer lead times and a lack of efficiency in the event of a challenge from the Technical Department and the need for further analysis.

In 2019, I integrated development quality directly into my team. Since then, measurements, analyses and decisions have been taken smoothly and quickly.

Quality, project managers and tooling experts work together on a daily basis. As soon as there’s a question about a measurement, we talk directly to each other, arbitrate on the same day and make rapid adjustments. This enables us to speed up fine-tuning, prioritise actions more effectively and avoid silos between departments.

This integrated approach is a real differentiator compared with other companies. I see it every time I present our organisation to customers. They immediately see the benefit and often remark on it. In their own structures, they often still have a strict separation between quality and technical, which slows them down.

We have also integrated tool purchasing into the department. This allows us to control internally all decisions relating to additional costs or technical choices for moulds, while always remaining consistent with the project challenges.

I’m Vincent Collard, Technical Director of the MORA Group and a mechanical engineer with a degree from UTC Compiègne. I began my career in subcontracting before spending 15 years in the automotive industry, where I developed sensors for engines and mechatronic systems for customers such as PSA, Renault, BMW and Ford. I managed development teams and supervised the entire project lifecycle, from design to production. I then decided to take on new challenges by becoming a key account project manager in the solar power plant sector, working with EDF and Aéroports de Paris on large-scale projects. Today, I put this experience in managing complex projects to work for MORA, supporting our customers with rigor and expertise.

Today, I put this experience in managing complex projects to work for MORA, supporting our customers with rigor and expertise.

Mora Group has been involved in product sterilization for almost ten years. This process mainly concerns products manufactured in cleanrooms and intended for the medical sector. We had noticed that some of our long-standing customers were sterilizing their parts themselves as soon as they received them.

As a rule, sterilization takes place at the final stage of the process. Once the products have been injected and packaged, they undergo sterilization before being sent to the end customer.

Mora Group’s commitment to sterilization management processes was prompted by the needs of a long-standing customer developing a pre-filled, single-use auto-injector.

This is a needle-free medical injection device, with MORA injecting the plastic components. As the drug comes into direct contact with the thermoplastic parts before being administered to the body, this is a particularly critical product. It is therefore essential to sterilize the injection nozzle assembled with its cover, a part manufactured by MORA, in order to eliminate any risk of infection for the patient in the event of contamination of the drug.

To guarantee optimum mastery of this requirement, we have called in specialists to deepen our knowledge and develop our skills, as well as our sterilization processes. However, this sterilization stage is not carried out in-house: we rely on subcontractors who are experts in this field.

In concrete terms, we deliver the packaged products to a service provider who takes care of sterilization. Once sterilization has been completed, the products are shipped directly to the end customer.

As mentioned above, once our parts have been produced, they are sent to the sterilizer. After processing, they are shipped directly to the end customer. However, we manage all the logistics and documentation associated with sterilization.

We are responsible for collecting and transmitting certificates of conformity. These documents include laboratory certificates attesting to the sterilization dose applied, LAL and Bioburden test reports, and the irradiation certificate validating that the pallets have received the minimum required dose in kilograys.

All these documents are then sent to the customer. However, due to the delays involved in issuing the certificates, customers may receive their pallets before these documents have been received. Only after all the sterility and sterilization certificates have been analyzed and validated can the customer officially release the batches for use.

This process goes far beyond conventional plastic injection molding production. It implies rigorous monitoring, an investment in logistical time and quality assurance. This expertise enables Mora to position itself as a trusted partner, capable of meeting the sector’s most stringent requirements.

We have chosen to bring this skill in-house, as it is fully in line with our global approach to managing the cleanliness and pollution of our products. This expertise is essential to guarantee rigorous control and perfect mastery of our internal processes.

To reinforce this approach, we have recruited a quality specialist in this field. Her role is central: she ensures internal controls, supervises interactions with the laboratories carrying out the tests, and ensures that our procedures comply with current standards and requirements. This internal integration enables us to optimize our monitoring, reinforce our responsiveness and ensure exemplary traceability throughout the process.

The Coq Vert community is much more than just a network: it brings together almost 2,500 business leaders committed to a voluntary approach to meeting major environmental challenges. By joining this group, Mora Group intends to play a full part in this collective dynamic and is committed to :

• Reduce climate disruption by adopting practices in line with carbon neutrality targets and investing in initiatives to help adapt to climate change.
• Make the ecological transition a necessity, a source of value creation and sustainable employment.
• Encourage, disseminate and promote technological and organisational innovation to accelerate the ecological transition of our industrial processes and products.
• Mobilise and unite our professional ecosystem by raising awareness of environmental issues among our partners, employees and customers.
• Make the ecological transition an opportunity to create sustainable value and responsible economic development.

Joining the Coq Vert community opens the way to a structured framework and concrete resources, enabling us to advance our environmental commitment:

• Specialised training: we now have access to exclusive training modules and educational resources that enhance our expertise in the fields of energy and ecological transition.
• An active network: through regular meetings, workshops and events, we benefit from a forum for dialogue and sharing with other committed players, encouraging the exchange of best practice and the emergence of collaborative initiatives.
• Increased visibility: by highlighting our actions, our participation in this community enables us to promote our environmental projects to our stakeholders and inspire other companies to follow suit.

Mora Group: committed to a sustainable future

For several years now, Mora Group has been fully integrating environmental and social issues into its business. This is illustrated by our participation in the Ecovadis programme, which assesses and values companies’ CSR performance. Joining the Coq Vert community represents a natural extension of this approach, and an additional lever for stepping up our efforts to promote the ecological transition.

We are convinced that this transition should not be seen as a constraint, but as an opportunity for transformation and innovation. It is forcing us to rethink our production models, to invest in sustainable technological solutions and to strengthen our role as a responsible player in our sector.

Beyond our own actions, our ambition is to unite all the stakeholders with whom we work: customers, partners, employees and suppliers. By collaborating with local and international players, we aim to contribute to a collective dynamic capable of meeting today’s climate and environmental challenges.

Vincent, could you describe your career path for us?

I’m Vincent Collard, Technical Director of the MORA Group, and a mechanical engineer with a degree from the UTC in Compiègne. I started my career as a project manager in the subcontracting sector, then spent 15 years in the automotive industry as a Tier 1 supplier.

I worked on the development of sensors for engines, gearboxes and mechatronic systems for customers such as PSA, Renault, BMW, Ford, Fiat, Mazda, Maserati and many other brands in France and internationally. I managed development teams of up to 30 people and oversaw the entire project lifecycle, from design to production.

This experience enabled me to strengthen my management skills and the management of complex projects. I then moved into a different sector, becoming a key account project manager for solar power plants, where I managed projects for customers such as EDF and Aéroports de Paris.

I then joined MORA as a project manager, before becoming Technical Director.

Can you tell us about your role as Head of Development at MORA and the team you lead?

As Head of Development, I manage a small team of around ten people:

Project/Process section

It includes the two project managers and the person in charge of industrial methods. The latter specialises in special machines and peripherals at the press exit. She helps us to define the presses, draw up the specifications, validate the equipment, ensure that it is put into operation and carry out all the on-site qualifications.

Quality development section

• Since 2019, quality has been integrated into development. This means that we can work more smoothly in project mode. We have an engineer in charge of quality-related documents, in particular qualifications, which are particularly demanding in the medical sector, with IQ, OQ, PQ reports, etc. We also develop protocols, i.e. preliminary documents, and define qualification criteria with customers. We also develop the protocols, i.e. the preliminary documents, and define the qualification criteria with the customers. The whole process is supervised by a validation master plan drawn up by the Quality Engineer.
• The quality engineer also draws up the measurement programmes on 3D machines, the R&R studies qualifying these measurements and the capability calculations qualifying the products. We also carry out the in-house fitting required for these measurements.

Le service comprend également une contrôleuse Qualité, qui travaille sur les rapports de métrologie. Elle alimente les différents rapports Qualité par ses analyses et inspections sur pièces et ses mesures.

Mould section

A mould expert with 30 years’ experience is both the tool expert and the tool buyer. He ensures consistency in exchanges with mould makers, using a common language. Under his supervision, two press set-up technicians are responsible for injection testing. They adjust the injection programme, carry out all the necessary tests and suggest improvements to optimise the processes.

Quotation section

The cost estimator is responsible for assessing the costs of all the RFQs we receive. These estimates are then sent to the sales department. There is a real continuity within the Technical Department between the costing being carried out and the project being taken over by the project manager. I think this involvement is essential, because the department takes ownership of the project, being responsible for both the costing and the project management.

We’re a relatively small team, but we work very closely together, which means we can be extremely responsive. The integration of development quality, mould purchasing and setting technicians within the department enables us to operate in a very coherent way. Working in a vacuum encourages fluid, rapid communication, which considerably improves responsiveness and the quality of information exchanged. This organisation is a real strength, giving us agility and fluidity in the management of our projects.

The customer can provide details of the production environment, for example in the medical sector, where clean environments are required, such as ISO 7 or ISO 8 rooms.

What is the internal development process like?

We work in project mode, which means that the project manager plays a functional hierarchical role. He or she is the customer’s single point of contact, enabling him or her to maintain an overview of all the project’s input and output data. Procedures must not be seen as a constraint; they must be transformed into effective tools for monitoring and ensuring the smooth running of the project.

Development is managed according to an internal procedure, no. 20, which includes six milestones called PR (Project Review), from PR1 to PR6. Each milestone marks a project review point, with specific input and output data. I take part in all these project reviews, which have to be signed off before moving on to the next milestone. As long as there are open actions, we can’t move on to the next review. This process allows us to structure and phase development over time.

Can you give us a little more detail on the procedure?

The process begins after the contract review, which marks the official launch of the project by the sales department (Kick off). Once the order has been received, the project can begin. I appoint the project manager and the associated team, which constitutes the handover between the quotation/offer phase and the project phase. The project manager The project manager then receives the budget, which includes the amount of purchases and the number of hours allocated to the project. After the contract review, the development procedure is launched.

Tell us about the quality aspect of the development process.

The quality part of the development process is crucial, in particular to ensure that the final product meets the customer’s requirements. This includes documentation and the implementation of checking fixtures from the earliest stages of development. We are responsible for designing the checking fixtures used in production, such as specific fixtures with three-dimensional checks performed by 3D measuring machines (probing or optical).

The measurement programme is designed by our team. In very demanding sectors such as the medical sector, and when we have moulds with 64 cavities, we develop specific fixtures enabling us to simultaneously check all the parts produced from a mould.

These tools must be qualified to guarantee their accuracy and reliability when measuring parts. Once qualified, they are used to assess part conformity and determine the capability of each critical rib. These checking fixtures are then transferred to the quality teams at the production sites, who use them to ensure rigorous and constant monitoring, guaranteeing part conformity throughout the manufacturing process.

Quality during the project also involves ensuring that all the qualification documents and associated test sheets are properly drawn up, from the protocols to the final reports.

And there can be no good process without appropriate Risk Analysis and Process FMEA; this approach is taken by the Development Quality department, involving the entire project team.

Tell us about the cleanrooms and processes involved in injection moulding.

The design of the cleanrooms that enable us to comply with ISO13485 was carried out by Mora’s development team. The entire 3D construction of the environment came from our department, with manufacturing being subcontracted. A new cleanroom was installed in 2017, followed by the second in 2019, the third in 2021, and the fourth in 2023. These facilities impose significant requirements in terms of cleanliness, clothing and environmental control.

Mr COLLARD, before highlighting the decoration business, could you briefly introduce yourself.

I’m Vincent COLLARD, Technical Director of the Mora Group. I am responsible for the development team based in Chambost-Allières, which works for all our sites in France, Portugal and Romania.

My career as a mechanical engineer, which began at the UTC in Compiègne, gave me a wealth of experience as a project manager for  car manufacturers and in the field of solar energy for large power plants. In 2016, after several years at Mora as project manager, I took over as the group’s technical director.

We are very pleased to announce that Mora Group has just acquired Manuplast SA, a Swiss company based in Ballaigues, canton of Vaud.

Manuplast SA is ISO 13485 certified and has a great portfolio of capabilities in high added value sectors such as medical devices, high end watchmaking and other technical industries.

These capabilities will perfectly complement the existing know-how of the Mora group.

For more details, please consult our communication release below