Explaining Injection Molding for Medical Devices

What Is Injection Molding for Medical Devices?

The medical injection molding process involves melting medical-grade plastics and molding them into the desired shape of medical devices. This process creates strong, durable equipment with impeccable surface finishes and precise measurements.

With additive manufacturing, medical professionals can now rely on high-quality injection parts that meet the strictest industry standards. Whether it’s intricate surgical tools or complex implantable devices, injection molding for medical devices ensures that every component is flawlessly fabricated for optimal performance. This medical parts manufacturing process is common to develop a wide range of components, devices, and parts, such as:

Knee and hip joint replacements
Surgical implants and pieces of equipment
Blood bags
Syringes
Catheters
Petri dishes
Healers
Test tubes

Different Kinds of Injection Molding for Medical Devices

Below are some different injection molding processes used to develop medical devices:

Plastic (Regular) Injection Molding

Plastic injection molding involves melting plastic polymers at high temperatures to create sterile and contaminant-free medical equipment. By reshaping the plastics in aluminum or steel molds, manufacturers can produce precise and customized medical devices that meet the highest standards of hygiene.

Insert Molding

Similar to overmolding, the insert molding technique involves molding a secondary component over an existing part, or the insert. What sets insert molding apart is that it is a single process and can be used with various materials, such as plastics, metals, or alloys.

Overmolding

Overmolding is an advanced technique that involves molding one or two components over an existing structure, resulting in a strong and durable grip. This two-step process, also known as two-shot molding, may have a longer production cycle, but the benefits are well worth it. With overmolding, manufacturers can create ergonomic handles to improve the comfort of everyday devices, which adds value and functionality to a wide range of items.

Liquid Silicone Injection Molding

Liquid silicone injection molding involves heating silicone to a liquid state and then molding it into various shapes, making it a versatile solution for developing medical products. Silicone, a plastic polymer, is specifically designed to meet the needs of the medical industry. However, it’s important to note that silicone molds may not be as durable as aluminum or steel molds, making this technique more suitable for small quantities and initial prototyping stages.

Different Plastics for Medical Injection Parts

Here are various medical-grade plastics used in injection molding for medical devices:

Polyetheretherketone (PEEK)
Polyetheretherketone (PEEK) is a high-quality thermoplastic known for its exceptional resistance to harsh environments, including radiation, high temperatures, chemicals, and wear and tear conditions. PEEK is perfect for creating medical and surgical implants and offers impeccable dimensional stability, even after being exposed to stress.
Polyethylene (PE)
Polyethylene (PE) is a versatile, durable medical-grade plastic polymer composed of thousands of ethylene polymers, giving it impressive tensile strength and rigidity. PE is also highly compatible with biological tissues and can withstand harsh environmental conditions, including sterilization. Thanks to these properties, PE is widely used in the medical field for manufacturing joint prostheses, connectors, tubing, pharmaceutical containers, and more.
Polycarbonate (PC)
Polycarbonate (PC) is transparent and has excellent mechanical properties. It’s tough, flexible, and resistant to abrasion, breakage, and temperature. Polycarbonate is also highly compatible with bodily tissues, making it ideal for manufacturing various medical equipment, from clear masks to protective gear and oxygenators.
Polypropylene (PP)
Polypropylene (PP) is a highly effective plastic polymer commonly used in medical injection molding. With its exceptional strength and resistance to cracking, radiation, impact, temperature, wear, and tear, it’s no surprise that it is a top choice in the healthcare industry. From life-saving syringes and connectors to essential knee and hip replacements, PP is the preferred material for producing critical components in healthcare.
Silicone
Silicone, a unique chemically inert compound similar to synthetic rubber, offers exceptional mechanical properties and compatibility with biological tissues. With its exceptional flexibility, silicone is the go-to medical-grade plastic polymer for manufacturing a wide range of products and devices, such as catheters, connectors, and tubing.
Polystyrene (PS)
Polystyrene (PS) is a high-quality engineering-grade plastic that’s not as flexible as others, but it has exceptional mechanical properties and is compatible with body tissues. Polystyrene offers excellent dimensional stability, making it ideal for creating critical medical components like petri dishes, culture trays, and diagnostic parts.

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The Benefits of Injection Molding for Medical Devices

Compliance With Industry Standards

Medical injection molding ensures that the produced components meet all necessary regulatory requirements set by the FDA.

Cost Effectiveness

Injection molding is not only automated, but it also significantly reduces labor costs. With computer-controlled precision, each part is efficiently produced, resulting in lower costs per unit.

High Precision and Accuracy

Injection molding guarantees tight tolerances and dimensional accuracy, which are crucial in the medical field. With injection molding, even the smallest deviations can be avoided, reducing the risk to patients.

High Volume Reproducibility

When it comes to medical products, such as syringes, gloves, and masks, the ability to produce high volumes with consistency is crucial. This is where injection molding excels. With this technique, once the mold is created, thousands of identical parts can be produced without the need for maintenance.

Key Takeaways

Are you searching for high-quality, precise mold manufacturing solutions for your medical devices? At Remington Medical, we offer excellent contract manufacturing services that ensure consistent, high-volume production.

Our injection mold manufacturing process is ideal for products and plastic parts that require large-scale production. With scalable injection molding machines, we can easily adjust to meet your needs with consistent, high-quality production every step of the way. Contact us today to learn more about injection molding for medical devices.