Fluoropolymers may be the solution to the Medical Glass Shortage

November 10, 2022  |  , , , ,

The shortage of glass has been an ongoing issue. Experts say the price of glass is on the rise as global supply chain issues continue throughout the world.  The glass shortage affects all industries that rely on glass for their containers, but right now, with the convergence of annual flu, the emergence of new COVID variants (Omicron), and the outbreak of Respiratory Syncytial Virus Infection (RSV) in children, the medical field is in dire need of glass for vials.

Silicon, which is one of the materials that is used in glass manufacturing has been in short supply for over a year.  Medical vials are made of Type I borosilicate glass, and this form uses the most silicon. The decreases in the recycling rates during the pandemic, are additionally hurting the production of glass vials.

Fluoropolymers such as FEP, PFA, and PCTFE are great alternative materials for glass. These fluoropolymers are superior to conventional plastics. Their inert, non-reactive, and unmatched durability makes their properties ideal for use in the medical industry. These fluoropolymers are also non-stick, ensuring the product does not adsorb to surfaces. They are also virtually impervious to chemical, enzyme, and microbiological attacks. All the benefits of FEP, PFA, and PCTFE make these fluoropolymers a perfect material to create vials out of, especially since they are injection moldable.

At Performance Plastics, we have extensive experience in injection molding fluoropolymers. We have developed proprietary tooling and processes enabling the injection molding of small, thin-walled, complex parts. Our expertise in fluoropolymers and injection molding can be the solution to the shortage of glass.

For more information on how to use fluoropolymers as your glass shortage solution contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.

 

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Teflon®- Why Machine when you can Injection Mold

September 13, 2022  |  , , , , ,

Performance Plastics specializes in the precision injection molding of technically complicated parts in advanced materials, eliminating the need to machine.

High performance plastic materials offer ideal properties when it comes to durability. Resins like polytetrafluoroethylene (PTFE/Teflon®) are known for their dielectric strength, low dissipation, chemical resistance, outstanding performance at elevated temperatures, and levels of coefficient friction. However, these unique properties can make molding some fluoropolymers quite difficult. Performance Plastics has found a way to offer the benefits of these materials by injection molding alternate fluoropolymers such as FEP and PFA.

At Performance Plastics, we are experts at precision injection molding. We have developed proprietary tool design software, processes and equipment enabling us to injection mold components having complex geometries made from challenging high-performance thermoplastic materials (PFA/FEP/PEEK®/PTFE/Teflon®) and highly loaded compounds. We utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations.

Switching from machining parts to injection molding parts can be very beneficial. Not only does injection molding help lower costs, but it also allows for highly efficient production, complexity in part design, and enhanced part strength. Injection molding produces uniformity, the ability to make millions of virtually identical parts.

Injection molding isn’t for every project, but it can be cost beneficial for applications producing more than 10,000 pieces of the same part year over year. At Performance Plastics, we serve a variety of industries, from medical & life science, aerospace & defense to diversified industrial.

To learn about how precision injection molding can replace machined parts, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.

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Benefits of Reshoring for Medical Device Manufacturers

June 28, 2022  |  , , , ,

Medical devices must be dependable and safe, and moving operations back to the United States allow companies to have better control over the entire operation – procurement, engineering, production, and distribution.  The result is a higher standard of quality in products.  Medical device companies and other advanced industries need to have extensive and precise control over the entire supply chain of their products.

As an American small business, Performance Plastics is pleased to see the trend of manufacturing operations moving back to the United States.  A range of economic and strategic factors due to the recent epidemic have tipped the scales exponentially since 2020.

While there are many benefits of reshoring, some of the most important reasons include:

  • Greater Control of Supply Chain

Getting all your moving pieces to work seamlessly can be a near impossible task, especially across language and time zone barriers.  One of the primary advantages of reshoring is that it allows you to tighten your supply chain.

  • Reduced Lead Times

The greater the distance between where your device is manufactured and where you are located, the longer you can expect your lead time to be.  However, distance is not the only factor.  When moving from one country to another, inspection and transportation times between countries can add up to 50% to your lead time.

  • Fewer Import Tariffs

Import tariffs vary from administration to administration, but they will always be in place.  The recent increase in tariffs have caused the cost advantages of manufacturing offshore to shrink.

  • Reduced Energy Costs

Recent changes to international gas and power prices have drastically increased the prices of manufacturing and transportation from other countries.  Impact on the environment and achieving higher sustainability are very important to consumers.

  • Potential to Improve Brand Perception

Although we live in an international community, the origin of a product still has an impact on the perception of quality.  Some lower cost manufacturing countries even have a perception of being “dangerous”.

Medical devices necessitate the highest quality standards possible, which can’t always be regulated in an offshore manufacturing environment.  The vast global, economic, legal and social changes are all very dynamic and unpredictable in nature – making relocating operations a more sustainable, stable and efficient choice.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics for medical device components. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at rreed@performanceplastics.com 

 

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High Performance Polymers – A Great Alternative for Medical Devices

June 9, 2022  |  , , ,

Diabetes care has seen several innovations through the years. One of the most important developments is the insulin pump, which for many patients provides an option to the traditional needle and syringe approach to insulin injections. Insulin pumps are small, computerized devices that are about the size of a small cell phone.  Insulin pumps deliver doses of insulin, the hormone that regulates blood sugar, on a pre-programmed schedule.

High performance polymers have enabled medical device manufacturers to go beyond the functionality of ordinary plastic materials to develop innovative devices for treating diabetic patients.  Resins such as FEP and PFA fluoropolymers are chemically resistant resin with outstanding properties and are currently used in numerous healthcare applications. Physical properties of resins such as high tensile strength, dimensional stability, excellent friction and wear characteristics and the ability to replicate fine features are important advantages as parts become smaller and thinner.

In developing new and advanced insulin delivery devices, resins offer unique advantages and have expanded the possibilities for innovative design and manufacturing. Medical grade fluoropolymers, such as FEP and PFA allow for the miniaturization of device components without the constraints of glass or ordinary plastic materials. With these capabilities, designers can now expand design performance and possibilities. Fine detail replication resulting from the material’s high flow and excellent dimensional stability properties position resins as an excellent material for lightweight and compact precision delivery devices.

Device components such as insulin storage require the use of a proven polymer materials. In addition to compatibility with insulin, purity and very low levels of leaching, resins provide excellent moisture barriers and extremely low water absorption, both necessary properties for optimal long-term drug container storage. These resins are also FDA approved and are compatible with all conventional sterilization methods from gamma to steam.

In future insulin delivery systems, the use of FEP and PFA resin components for various parts of the device will continue to rise. With the advantages engineering polymers offer for design innovation and performance, resins will continue to be the material of choice for delivery applications.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds. For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at rreed@performanceplastics.com.

 

 

PFA plastic (Fluoropolymer) Thermoplastic Components

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Ultem® Use in Medical Applications

April 20, 2022  |  , , , ,

Ultem Polyetherimide is a material widely used in the medical industry.  It is a highly sought-after thermoplastic for its weight saving characteristics and for its use in reusable autoclave sterilization components.  Thermoplastic resins become more pliable at warmer temperatures which combined with strength characteristics, thinner walls and larger inner diameters make it a great option for medical tubing such as medical devices.

Thermoplastic polyurethanes dominate the catheter market and are used in some diagnostic and guiding designs. Extruded thermoplastic or thermoset materials are often used in cardiology or interventional radiology.   Polyamides and polyamide block copolymers dominate the percutaneous transluminal coronary angioplasty catheter market. They are the polymer of choice for balloon catheters and for stent delivery catheters.

 

Thermoplastic urethanes and polyether block amides are perhaps the most used thermoplastic elastomers in applications such as catheter tubing, balloons, wound dressings, surgical drapes, storage bags, strain reliefs and numerous other medical device applications.

Ultem is now widely used in:

  • Structural Medical Components
  • In Vitro Diagnostics
  • Medical Respiratory Devices
  • Infusion Pumps
  • Radiation Therapy Systems

Ultem has exceptional dimensional stability and machinability which makes it suitable for intricate medical devices. It can be molded with different materials like glass fibers, minerals, carbon fibers, etc. to enhance the mechanical strength of the products.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. Ultem® is an amorphous material, which can cause complications during the injection molding process. A specific set of conditions, equipment, and processing procedures must be followed to effectively injection mold Ultem®. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

Ultem® is one of the many high-performance polymers in which Performance Plastics specializes.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales and Marketing at 513.321.8404 or email at rreed@performanceplastics.com

 

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Plastic’s Edge over Metal in Medical Device Fabrication

February 21, 2022  |  , , ,
Thermoplastic medical spinal implant component, precision thermoplastic medical check valve, non-contaminating Thermoplastic medical valve component, precision thermoplasticmedical spinal implant component, non-contaminating medical spinal implant component

High Precision, PEEK, Thermoplastic Medical Spinal Implant Component

As technology continues to advance, medical device designers are being asked to increase performance and longevity of devices while decreasing costs. One of the most effective methods of achieving both goals is through a metal-to-plastic conversion using a medically compatible resin.

Newer polymers allow for the design of multiple features into one molded component and can replace metal components or multiple smaller parts. By improving the product design and manufacturing process with the latest materials and plastic manufacturing techniques, medical device designers can improve performance of the medical device while reducing its cost.

Medical devices continue to get smaller and more complicated. The size and complexity issues present opportunities for metal-to-plastic conversion. Small tools often are used by professionals who are gloved, and resins offer the ability to apply texture and reduce weight. By using a material that provides improved wet-grip characteristics and ergonomics, designers are able to improve the overall functionality of products. The use of properly selected thermoplastic elastomers (TPEs) allows for products that withstand sterilization to be made more effectively.

Instruments that must be repeatedly cleaned and sterilized, sometimes multiple times a day such as dental instruments, can now be made from high-performance materials such as polyether imide (PEI), or polyetheretherketone (PEEK) polymers. These improvements result in better medical devices often at lower manufacturing costs.

Medical resins are ideal for bone implants. Devices made from PEEK polymer are a better match to the normal flexibility of a bone for implants. When a stainless-steel implant is used, the adhesion between the implant and bone tends to loosen over time, because the bone has a small amount of flexibility. A stainless-steel implant does not flex.

By using PEEK polymer as the implant stem, rather than traditional stainless steel, the polymer has close to the same flexibility as the bone and there is a reduced tendency for the implant to loosen over time. This compatibility between bone and polymer makes a more effective medical device — one that will allow better long-term outcomes, especially as the average life span of an implant increases in tandem with the life expectancy of the general population.

 

 

https://www.plasticstoday.com/medical/plastics-edge-over-metal-medical-device-fabrication

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Metal to Plastic Conversion for Medical Applications

February 3, 2022  |  , , , , , , ,

With the population aging and improving technology, medical device designers are being asked to increase performance and longevity of devices as well as decrease costs.  One of the most effective methods of achieving both these goals is a metal-to-plastic conversion.

Plastics can be used to replace even the most sophisticated medical device by incorporating simple design modifications.  High performance polymers offer the same strength and rigidity as some metals along with some additional advantages.

Advantages of the medical resins include:

  • Reduced Device Weight
  • Increased Design Freedom – Moldability of all Features
  • Improved Functional Aesthetics
  • Reduced Sterilization Burden
  • Improved MRI Compatibility

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics.  Ultem® PEI and Peek are premium medical grade resins that are ideal for the manufacturing of medical parts and components.  Medical grade resins provide excellent mechanical properties and are highly resistant to chemicals and thermal degradation, making them highly desirable materials for plastic injection molded products within the medical industry.

At Performance Plastics, we utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations. Our expertise in process control allows us to effectively injection mold medical resins into parts with extremely tight tolerances. This gives us the ability to provide an injection molded part made from the highest strength and stiffness of any medical resin.

PEI is one of the many high performance polymers Performance Plastics specializes.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, our Vice President of Sales and Marketing at 513.321.8404 or email at rreed@performanceplastics.com.

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Torlon (PAI) Polyamideimide for Medical Applications

December 7, 2021  |  , ,

Torlon (PAI) Polyamideimide is one of the highest performing, melt-processable thermoplastics.  Its compressive strength is double that of PEEK when unfiled, and about 40% higher than ULTEM PEI.  Torlon is frequently used in medical applications due to its high strength and resistance to deformation.  It’s wear resistance adds up to long product life for peristaltic pump rollers and bushings for prosthetics.

Parts manufactured from Torlon plastic will exhibit high levels of tensile and compression strength that ensure good mechanical capability. Additionally, Torlon material provides elevated levels of toughness and rigidity.

In its medical grades, Torlon (PAI) offer high modulus, radiolucency, sterilization-compatibility and high wear resistance, making it ideal for components. PAI’s extremely low coefficient of linear thermal expansion and high creep resistance deliver excellent dimensional stability over its entire service range.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics.  Torlon® is a reactive polymer, which can cause complications during the injection molding process. A specific set of conditions, equipment, and processing procedures must be followed to effectively injection mold Torlon®. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

We utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations. Our expertise in process control allows us to effectively injection mold Torlon® in parts with extremely tight tolerances. This gives us the ability to provide an injection molded part made from the highest strength and stiffness of any commercial thermoplastic.

Torlon® is one of the many high performance polymers Performance Plastics specializes.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, our Vice President of Sales and Marketing at 513.321.8404 or email at rreed@performanceplastics.com.

 

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What is PFA and What Is It Used For?

September 21, 2021  |  , , , ,

PFA plastic (perfluoroalkoxy) is a tough, flexible fluoropolymer that is used for flexible and reusable medical equipment pharmaceutical and semi-con devices when chemical resistance, high purity, and flexibility are required.

PFA plastic is generally used for medical, pharmaceutical and semi-conductor plastics due to its extreme resistance to chemical attack, optical transparency, and overall flexibility. Keeping material purity is of critical importance in most injection molding applications, but particularly the medical, pharmaceutical and semi-conductor industries.

Devices used for medical, pharmaceutical measurement and semi-conductor are frequently exposed to harsh biological and chemical elements. Parts manufactured or coated in PFA materials provide good resistance and are an effective solution for avoiding contamination.

PFA is such an optimal material, that in some cases it can even replace stainless steel in medical devices.   PFA handles high temperatures and pressure well and is resistant to biological impurities. PFA is a go-to option for moving elements in medical devices because of its stiffness and long life, while providing flexibility and resistance to cracks

Many PFAs are used in pharmaceutical industry because of mandated regulations for process component materials. PFA is very versatile in how parts can be manufactured, and it lends itself well to extrusion, injection molding, transfer molding,  blow molding and compression molding.  You will often see PFA in lab equipment because of its outstanding chemical inertness and flexibility.

PFA resins are fully fluorinated polymers specifically designed for the high demanding applications of the semi-con industry.  The high purity composition of PFA addresses the requirement for minimum extractables while proving improved flex life and excellent chemical stress crack resistance.

PFA Properties

  • Chemically stable
  • Dielectric strength
  • Non-flammable
  • Chemical resistance
  • Anti-stick properties
  • Low friction
  • FDA approved
  • High purity
  • UV Resistant
  • Translucent
  • Low moisture absorption

PFA is one of the many advanced fluoropolymers Performance Plastics can mold within extremely tight tolerances.  For more information, please contact Rich Reed, Vice President of sales and marketing at 513.321.8404 or rreed@performanceplastics.com.

 

 

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Injection Molded Peek Seals

July 21, 2021  |  , , , , , ,

Performance Plastics offers the expertise and technology to produce net shape seals in high-performance materials such as PEEK.  PEEK (polyetheretherketone) polymer is a high-performance thermoplastic material with outstanding mechanical, thermal and chemical resistance properties

Seals have been used since ancient times and have evolved into a wide variety of shapes and materials. Mechanical seals are used to seal the openings of and joints between mechanisms to contain pressure and form a barrier to prevent the fluid (water or oil) used by a machine from leaking to the external environment.  Commonly used in pumps, motors, and compressors, seals are one of the most essential components to ensure a machine operates reliably and effectively.

PEEK is an organic thermoplastic polymer that offers excellent mechanical and chemical resistance properties for applications that are maintained at high temperatures. PEEK seals can be heated, cooled, and heated again without degradation since they are composed of thermoplastic materials.

PEEK polymer seals are well suited for demanding applications such as aerospace, automotive, and medical because of their robustness. They offer outstanding chemical resistance over a wide range of temperatures and are an excellent option for extreme applications where failure is not an option.  Performance Plastics’ team of experienced engineers possess the expertise to design technically challenging seals and offer complex solutions across a wide range of industries.

For more information on how Performance Plastics can solve your seal selection   challenges, please contact Rich Reed, VP Sales & Marketing at 513.321.8404 or rreed@performanceplastics.com.

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