Medical Tube Extrusion

Medical extrusion involves the process of forcing molten thermoplastics through a die to achieve a desired shape upon cooling. Polyzen is a trusted leader in the extrusion of medical grade tubes. Our capabilities include extrusion of small diameter tubing used for catheters, drainage tubes, drug delivery, and much more. These extrusions are available in single and multi-layer material configurations.

Small tubes used for minimally invasive diagnostic and therapeutic procedures often require materials with unique performance properties, including radiopacity and hydrophilicity. Our material science experts are available to develop custom polymer formulations to ensure optimal product performance and extrusion quality. Our in-house tool room provides quick turnaround of tight-tolerance dies for prototype and production extrusion runs.

Medical Tubing Applications

As an innovative specialist in the extrusion of medical-grade polymer tubes, Polyzen serves a multitude of medical device applications. Our in-house medical extrusion capabilities include:

Small-Diameter Tubing

Precision plastic tubing is used in a broad range of diagnostic and therapeutic procedures, from complex minimally invasive vascular catheters to central venous (CV) lines and drainage catheters. These tubes are often integrated with bags, balloons, and other components to medical devices that range from Class I containment systems to Class III implantable devices.

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Bags, Tubes, & Barriers

Large-diameter, thin-wall extrusions are used to create a plethora of devices used throughout the healthcare industry. Melt extrusion can be used to produce single layer lay-flat tubing which can be seam welded to produce a wide variety of medical covers and containers.

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Polyzen Tube Capabilities

Lay-Flat Tubing

Typical Dimensions
  • Width ≈ 0.25 – 3.0 inches
  • Wall thickness ≈ 0.0005 – 0.004 inches
Typical Materials
  • Thermoplastic Polyurethanes (TPUs)
  • Thermoplastic Elastomers (TPEs)
  • Polyamides (nylons, Pebax*)
  • Ethylene Vinyl Acetate (EVA)
  • Polyolefins (PP, PE)
  • Fluoropolymers (PVDF)
  • Custom colors & additives
Quality & Testing
  • Drop gauge
  • In-line laser gauge
  • Class 7 clean room production
Secondary Processing
  • Die cutting
  • Assembly

Catheter Tubing

Typical Dimensions
  • Maximum OD ≈ 0.350 inches
  • Minimum ID ≈ 0.006 inches
  • Wall thickness ≈ 0.005 + inches
  • Tolerances ≈ 0.0005
Typical Materials
  • Thermoplastic Polyurethanes (TPUs)
  • Thermoplastic Elastomer (TPEs)
  • Polyamides (nylons, Pebax*)
  • Fluoropolymers (PVDF)
  • Radiopaque filled compounds
Quality & Testing
  • In-line laser gauge measurement
  • Ultrasonic measurement
  • Die cutting
  • Laser cutting
  • Tipping
  • Marker bands
  • Laser drilling
  • Eye coring/skiving
  • Bonding – UV, solvent, heat
  • Insert hub molding
  • Laser drilling/cutting
  • 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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