EnsoETM

To meet our client's needs we redesigned the tip to integrate a thermistor at the far end. In order to accommodate this added probe the tip needed to be lengthened and channels were added to allow the wire to exit the device. Using the insulated properties of silicone I was able to calculate and verify with testing that extending the tip length by 2in would be sufficient to isolate the probe from the temperature of the water and sense core temperature within 1 C of the actual core temperature. The silicone coated wire ran though a central channel of the device where it exited at a molded junction.

In order to test these parts I needed to mold prototypes. For the modified distal tip I designed a four part mold that I could inject with a two part silicone and then cure. I went though multiple iterations of mold design and molding procedures to achieve my finished result. One of the major challenges faced was fully filling such a high aspect ratio part. To overcome this I tweaked vent sizes, volume injected and degas procedure.