Medical Dip Molding, Coating, & Casting

Dip molding and casting of medical balloons and other components involves dipping a positive mold in a liquid resin solution, allowing the resin to cure, then demolding of the component. The same process can be used to coat components.

Dip molding is ideal for producing thin-walled, highly compliant balloons, coating stents and wires, casting specialty films, and more. Dip molding does not produce seams or mold parting lines on components, and it is ideal for fast prototyping and large-volume production runs. Dip coating can provide soft grips or protective coatings to surgical instruments, containers, or components.

Polyzen has extensive experience and in-house capabilities to dip mold with thermoplastic polyurethanes (TPUs), thermoplastic elastomers (TPEs), silicone rubbers, and other polymer dispersions or solutions. In-house polymer solution formulation and mold development allows us to provide quick turnaround on dip molded, cast, and coated prototypes.

Dip Molding Applications

Solution coating and molding is extremely versatile and has been used for a wide range of applications from gloves to vascular stents. Several high-performance medical device components that use this process include:

Medical Balloons

Dip molding allows for the development and production of thin-wall, highly compliant balloons for a variety of medical applications. These include everything from low-pressure balloons to condoms, gloves, and other similar products.

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Barrier Sleeves

Dip molding is ideal for producing multifunctional barrier sleeves in an array of materials and shapes. We can also add performance enhancing coatings to molded sleeves, including antimicrobial, hydrophilic, and drug coatings.

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Stent, Metal Scaffold, or Specialty Device Coatings

Solution dipping a proven technique for coating all types of components, including stents, wire cages, scaffoldings, sensors, and scope tubing. Coatings can be used to protect the underlying structure or add function benefits, such as enhanced lubricity (hydrophilic coatings), infection protection (antimicrobial coatings), or drug delivery (coatings with active pharmaceutical ingredients).

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Polyzen Dip Molding & Coating Capabilities

Typical Dimensions
  • Thickness ≈ 0.0003 – 0.020 inches
Typical Materials
Quality & Testing
  • Laser Micrometer
  • Measurement Microscope
  • Drop Gauge
  • Pressure Decay Leak Testing
Secondary Processing
  • Laser Cutting/Drilling
  • Assembly

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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