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Explore our suite of solution processing capabilities around molding, coating, casting, and encapsulation.

Dip Molding

Polyzen engineers have perfected an art over the last 30+ years to create unique geometries and shapes from a multitude of polymers. Our solvent based systems enable the molding of very thin membranes that can be used for a variety of applications. Polyzen prides itself in achieving consistent wall thickness profiles of 0.0005” through utilizing multi axis machines.

Applications that Polyzen has assisted on:

  • Neurology balloons/implants
  • Ophthalmic balloons and shunts
  • Middle Ear balloons
  • Blood Filtration devices
  • Endotracheal balloons
  • Breast Implants
  • Implantable cardiovascular blood pumps
  • Implantable pumps for LVAD’s
  • Implantable intragastric balloons
  • Intra-Aortic Balloons
  • Urology balloons
  • Device delivery bellows
  • Barrier sheathes / sleeves
  • Gloves
  • Condoms

Materials that Polyzen has been able to solutionize and mold:

  • TPU
  • Silicone
  • TPE
  • PVDF
  • Bioabsorbable Polymers (PLGA, PCL, PLA)

Dip Coating / Spray Coating / Encapsulation

Polyzen has a strong background in material science and polymer formulations. Medical devices that require coatings or encapsulation aid in the delivery, placement, or retrieval of those products. Coatings also serve as a barrier to restrict blood flow or prevent tissue adhesion. Polyzen has utilized its material science expertise in compounding certain additives within polymers to create various functional requirements such as increasing or decreasing lubricity, creating conductive surfaces, impregnating anti-microbial additives or drug eluding surfaces, and many more. Polyzen has been able to create polymer encapsulations with very low profiles – under 0.0005”

Applications that Polyzen has assisted on:

  • Clot Retrievers
  • Embolic protection frames
  • Peripheral stent grafts
  • Non vascular stents
  • GI / Biliary stents
  • Retrieval baskets
  • Microcatheters

Materials that Polyzen has been able to solutionize and utilize as a coating:

  • TPU
  • Silicone
  • TPE
  • EVA
  • Hydrophilic Additives
  • Color Additives
  • Antimicrobial Additives
  • Conductive Additives

Casting / Solution mixing

Polyzen has been known to test the processing limits of polymers. Spin casting uses a centrifuge system to cast ultra-thin membranes that can be utilized for drug delivery applications. Liquid casting sheets or creation of coupons is another way to take advantage of a variety of polymer properties in a cost-efficient manner. Polyzen has been able to successfully suspend dense particulate and homogeneously disperse the polymer into a film.

Applications that Polyzen has participated in:

  • Phase 1 – API integration for wound care delivery
  • Phase 1 – API integration/delivery for ophthalmic / glaucoma therapy
  • Phase 1 – API integration/delivery for vascular therapy
  • Tungsten loaded films for radiation shielding
  • Dermal Fillers
  • Creation of polymer-based adhesives / glues for device assembly

Materials that Polyzen has worked with for casting:

  • TPU
  • Silicone
  • PLGA, PCL, PLA
  • EVA
  • Radiopaque Additives/Metals

Testing/Measurement

Polyzen Methods of Testing / Measurement for Solution Processing:

  • Laser micrometer/non-contact systems
  • Microscopes
  • Drop guage
  • Pressure decay leak testing

Polyzen Facility / Machines / Equipment:

  • In house tool shop
  • Humidity controlcontrolled roomss/chemical hoods
  • ISO Class VII Cleanroom manufacturing
  • Custom sized dip vats and machines
  • Single-axis dip machines
  • Multi-axis dip machines
  • Spray coating systems
  • Spin Casting systemsing
  • Plasma chamber
  • Vacuum chamber

If you would like to receive a quote from Polyzen, please fill out the form below, and click “Request Your Quote”. We encourage you to use the “Product Information” box to provide as much technical information about your product as possible, as this will help to speed up the quoting process.

About Polyzen

Polyzen, Inc. is a leading contract developer and manufacturer of custom medical-grade polymer components and products for medical device manufacturers worldwide. With fully equipped facilities in Apex, NC, we’re capable of taking any customer’s concept from prototype to full-scale production. We offer a variety of technologies and turnkey services to meet the most demanding application and regulatory challenges.

Polyzen Can Help

Rely on Polyzen’s expertise to bring your medical polymer device needs to reality.


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