DIP MOLDING/COATING & ENCAPSULATION

MEDICAL DEVICE
SURFACE MODIFICATIONS & COATINGS

Surfaces of medical device components often require modification to improve performance or maximize bond adhesion. Polyzen has in-house expertise in a variety of techniques used to enhance surface properties of plastic parts.

Medical polymers provide mechanical, thermal, electrical, and other properties necessary to meet the requirements of each medical device. However, additional performance characteristics are often required for the surface of device components. These include:

  • Hydrophilic coatings to reduce friction in aqueous environments
  • Antimicrobial coatings to reduce the colonization of bacteria on devices that cause infection
  • Anti-thrombogenic coatings that reduce the risk of blood clots
  • Anti-static coatings that reduce the buildup of electrical charges
  • Anti-coagulant coatings, such as heparin, that thin blood and prevent blood clotting
  • Active pharmaceutical ingredient (API) coatings for drug delivery
  • And much more

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)

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

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

Polyzen Methods of Testing / Measurement for Solution Processing:

  • Laser Micrometer/non-contact systems
  • Microscopes
  • Drop Gauge
  • Pressure Decay Leak Testing

Polyzen Facility / Machines / Equipment:

  • In house tool shop
  • Humidity controlled rooms/chemical hoods
  • ISO Class VII Cleanroom manufacturing
  • Custom sized dip vats
  • Single-axis dip machines
  • Multi-axis dip machines
  • Spray coating systems
  • Spin Casting systems
  • Plasma chamber
  • Vacuum chamber
SURFACE TREATMENT FOR
COATING & BONDING

Surface modifications, such as plasma treatment, are used to prepare plastic surfaces for adherence of a coating or to increase the bond strength between two dissimilar materials. Plasma treatment refers to a plasma reaction that either results in modification of the molecular structure of the surface or atomic substitution. Only a few atomic layers on the surface are involved in the process, so bulk properties of polymer remain unaltered by the chemistry. Plasma treatment with benign gases such as oxygen or nitrogen provides adequate surface activation for enhanced wetting and adhesive bonding of materials such as polyethylene or polypropylene.

TYPICAL
POLYMER MATERIALS

Our expert team of material science specialists works directly with each customer to develop and optimize the surface of medical device components. Our team has experience modifying surfaces of components from a wide range of materials. These include thermoplastic polyurethanes (TPUs), thermoplastic elastomers (TPEs), polyamides (nylons, Pebax*), thermoplastic polyesters (Hytrel*, Arnitel*), ethylene vinyl acetates (EVAs), polyvinylidene fluoride (PVDF), polypropylene, polyethylene, and more.

Polyzen Can Help

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