Medical Film Extrusion

Medical extrusion involves the process of forcing molten thermoplastics through a die to achieve a desired thickness upon cooling. Flat dies and post-extrusion roller systems allow for the production of thin films used for thermoforming trays, welding bags, creating barrier sleeves and countless other medical applications. Polyzen is a trusted leader in the extrusion of single and multi-layer medical and non-medical films. We have dies and extruders in multiple sizes to support customers in the development of new films and high-volume production and our medical films and laminates are manufactured in a clean room environment.

Further, Polyzen regularly partners with  resin manufacturers to develop new resins. Through our collective experience, Polyzen has worked with a wide range of materials in a wide range of processes. We offer lab day machine rentals and engineering support to help resin manufacturers innovate, develop, test, and deliver the resins of the future.

Medical Film Applications

As an innovative specialist in extruding medical-grade polyurethane and other thermoplastic films, Polyzen serves a multitude of potential customer applications from disposable balloons, bags and sleeves to long-term implants. Our in-house medical film extrusion capabilities also include:

Coating & Laminations

Precision lamination and coating of dissimilar materials provides structures with discrete surface properties. Polymer films and coatings can provide protective barriers to foam, plastic, paper, fabric, and other structures. These can ensure medical devices resist water, vapor, heat, UV light, bacteria, and more.

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Breathable Films

Films with high moisture vapor transmission rate (MVTR) properties are commonly used in wound care and medical garment applications. These films are typically impermeable to liquid, water and bacteria but permeable to moisture vapor and atmospheric gases.

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Barrier Films

Multi-layered or laminated films comprised of multiple materials can provide barriers against moisture, oxygen, light, chemicals, and more. Barrier Films are often produced using multi-layer processing technologies to adhere dissimilar materials with unique performance properties. Polyzen’s barrier films can be made in a Class 7 Clean Room environment, making them more suitable in the packaging of critical medical devices or as components in devices used for diagnostics, wound care, and more.

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Polyzen Film Capabilities

Typical Dimensions
  • Width ≈ 1 – 48 inches
  • Thickness ≈ 0.0005 – 0.060 inches
Typical Materials
  • Thermoplastic Polyurethanes (Aromatic and Aliphatic TPUs)
  • Thermoplastic Elastomers (TPEs)
  • Polyamides (nylons, Pebax*)
  • Ethylene Vinyl Acetate (EVA – Ethylene-vinyl acetate)
  • Polyolefins (PP, PE, LDPE, HDPE)
  • Fluoropolymers (PVDF)
  • Colors and Additives (Color Matching, Additives, Anti-Static, Fire Retardant, Heat Stabilizers, High Clarity, UV Stabilizer, and more)
  • Custom thermoplastic materials & formulations (below 500°F)
  • Monolayer
  • Multi-layer/Barrier
  • Lamination (fabric, polypropylene carrier, paper)
  • Co-extrusion (A-B or A-B-A)
Surface Finishes
  • Gloss / Gloss
  • Matte / Matte
  • Gloss / Matte
Quality & Testing
  • Drop gauge
  • In-line X-ray gauge
  • Clean room production (optional)
In-Line/Secondary Processing
  • Lamination
  • Slitting
  • Die cutting
  • Welding
  • Thermoforming
Order Size
  • No minimum orders
  • Specialize in both development and large volume production runs

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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