Plastic parts are the key element in the design and the functioning of many medical devices, parts, and equipment. They are the main component of almost all medical products because of their durability, the fact that they can be used only once, the ease of storage, the versatility of the size and the possibility of being molded into complex shapes. Among the different manufacturing processes, medical plastic injection molding is among the most prominent technique used for the production of plastic parts, equipment, and more in the medical industry.
In this blog post, we explore the various reasons why companies choose the plastic injection molding in the medical sector instead of other manufacturing processes.
Benefits of Using Medical Injection Molding Products
Here are some of prominent benefits of medical injection molding discusses below.
1. High Percision & Consistency
Injection molding is an effective technique for producing medical products because of its precision and inch-percision in part making. It employs the high-pressure injection of the specialized medical-grade materials into the custom molds, which guarantees that each component is accurately shaped as required, even at the microscopic level. This degree of precision is very important in healthcare, where even the slightest changes can affect the treatment of the patient. For the manufacturers, this implies that there will be fewer defects and lower quality control costs, which proves the advantages of injection molding.
2 Cost Optimization
The high volume batches production is a factor that leads to the reduction of the production costs. Although the tooling costs may be higher at the beginning, the per-part cost becomes much lower when producing the similar parts in bulk than the other manufacturing processes.
3. Durability & Aesthetics
The third advantage of the use of 3D printing is the enhanced durability and material strength. Plastic injection molding in the medical field uses high-pressure techniques to produce parts that are characterized by the high durability and strength. These parts usually last for a long time, hence, the hospitals and healthcare providers save a lot of money in the long run.
4. Material Diversity:
Injection molding of plastic is a process that uses a large number of materials, such as ABS, Polypropylene (PP), Nylon, PET, Polycarbonate, and various resins. Every material has its own properties like heat resistance, strength, weight, biodegradability, and so on. This flexibility allows the healthcare professionals to select materials that are suitable for specific applications, thus, the medical components become more functional and efficient.
5. Ability to Sterilize
The compliance to medical products sterility is critical for medical injection molding parts and components. Products produced through plastic injection molding in the medical industry can be easily sterilized, thanks to attributes like heat resistance and strength. This feature makes it a preferred process in many medical regulations and certifications.
6. Flexibility for Customization
Plastic injection molding in the medical field allows for easy customization due to the nature of the materials used. This capability facilitates the manufacturing of a wide variety of medical parts at scale, meeting diverse needs effectively.
7. Sterilization Capability
Sterilization is the key in the production of medical injection-molded parts and equipment. Plastic injection molding in the medical field makes it possible to sterilize easily because of the heat resistance and strength. This attribute not only corresponds to the many medical regulations and certifications but also guarantees the safety and hygiene of medical products.
8. Customization Flexibility
The materials used in plastic medical molding shows compatible features to fulfil customization needs. This adaptability enables the production of a wide variety of medical parts at a large scale, which in turn meets the specific needs and improves the overall product functionality.
9. Minimized Waste Generation
The process of plastic injection molding in the medical industry is the one that allows for the reduction of wastage. The leftover plastic from production can be easily used for the next manufacturing runs, thus, the waste will be much less than the waste from the metal in other manufacturing methods.
The search for a reliable manufacturer for plastic injection molding is a tough task for medical companies and startups. Problems such as the reluctance of manufacturers to accept small orders, lack of technical expertise regarding suitable materials and processes,
a wide range of SKUs to be produced, difficulty in sourcing raw materials, among others, are common hurdles. The injection molding technologies and services accessible with just a few clicks comprise:
- Soft tooling technology
- Production tooling technology
- The thermoplastic injection molds (2 plates, 3 plates, hot runner) are a type of mold that consists of 2 plates, 3 plates, and a hot runner.
Molds for thermoset components (compression molds) are the ones that are used for the thermoset components which are the components that are compressed.
The process of over-molding and insert molding is the one that is used to create a part that has the properties of two or more different materials.
These options give a wide range of features that are suitable for the different manufacturing needs.
Injection Molding Ideally produce Medical Enclosures
Injection molding is notably right technique to create enclosures and cases for various medical use implantable devices. Although other methods such as CNC machining or vacuum casting are available, they are usually slower, use more raw materials and hence, have higher manufacturing costs per part. These substitutes are usually more appropriate for low-volume or custom projects where tool investment is not possible. On the other hand, the medical device injection molding has the advantage of faster production, lower costs per part, and the use of medical-grade plastics, which makes it the perfect option for the manufacturing of cases and enclosures.
Summary
To sum up, the advantages of injection molding in the medical device manufacturing, which are the intricate designs and the customizable solutions, are obvious. With the development of medical technology, this method will be undoubtedly the key factor in the production of new devices that will improve the patient health, and alongside, the driving force of the healthcare advancements worldwide.
FAQ’s
Q1. What is molding in medical industry terms?
The shaping of the fetal head to fit the birth canal dimensions occurs as it goes down the pelvis.
Q2. Why plastics are notably considered more compatible for medical devices’ manufacturing?
The use of plastic-injected medical devices helps to cut the medical costs, prevent infectious diseases, and manage pain. Advanced polymers are mostly used in medical device prototyping, especially for the improvement of prosthetics and the creation of devices that decrease the infection risks. Injection molding plastic devices had no negative impacts on patient safety.
Q3. Why PEEK, and Polycarbonate materials are used in injection molding?
Polycarbonate: This clear plastic is strong and used in medical tubing because of its high strength, heat resistance, low moisture absorption and FDA approval.
PEEK: It’s a FDA-approved medical grade plastic with high chemical resistance, crack and fatigue resistance, autoclave sterability. Further, it has a high flammability from other grade plastics.