Medical Film Welding

Heat welding is commonly used to produce complex medical device shapes from polymer films. Film welding technology is ideal for low and high-volume production of products ranging from low-pressure balloons to bags, barrier sleeves, and sheaths for medical devices.

Using radio-frequency (RF), impulse, or ultrasonic welding techniques, Polyzen is able to produce weld seams as thin as 0.010 inches that retain mechanical strength similar to the film substrate. Polyzen’s in-house thin film welding capabilities includes experienced personnel and company-owned welding equipment needed to weld all types of polymer materials. This includes single and multi-layer elastomeric films.

Thin Film Welding Applications

Polyzen is well-known in the medical industry for our ability to weld a broad range of polymer materials with the utmost quality, precision, and reliability. Further, customers typically come to Polyzen for their most unique and complex designs. Applications for our thin film welding technologies include:

Medical Balloons

Medical balloons can be extruded, formed, and welded in single or multi-layer constructions for a range of medical and biopharmaceutical industries. These balloons can be inflated by liquid or air to desired shapes for specific applications.

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Sheaths & Sleeves

Thin film welding is ideal for producing custom barrier sheaths and sleeves that protect scopes and other instruments during medical procedures. Sheaths and sleeves can be created in precise custom shapes to suit any unique instrument.

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Bags, Bladders, & Membranes

Medical bags produced from welding thin films are used for organ bags, specialty bags, blood bags, saline bags, nutrient bags, and more. Film welding is also used to produce multi-pocket bladders, membranes, and controlled expansion containers.

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Polyzen Film Welding Capabilities

Typical Dimensions
  • Film Thickness ≈ 0.0005 – 0.030 Inches
  • Seam Width > 0.020 Inches
Typical Materials
  • Thermoplastic Polyurethanes (TPUs)
  • Thermoplastic Elastomers (TPEs)
  • Polyamides (Nylons, Pebax*)
  • Ethylene Vinyl Acetate (EVA)
  • Polyolefins (PP, PE)
  • Fluoropolymers (PVDF)
  • Polyvinyl Chloride (PVC)
Welding Options
  • Direct Heat
  • Impulse
  • Radio Frequency (RF)
  • Ultrasonic Welding
  • Laser Welding
Quality & Testing
  • Drop Gauge
  • Tensile Strength
  • Pressure Decay Leak Resistance
Secondary Processing
  • Die Cutting
  • 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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