High-performance thermoplastic-molded parts for medical applications offer many advantages that can’t be achieved with other materials.

Advantages of thermoplastics for medical devices

  • Can replace metals in applications offering benefits like lighter weight and biocompatibility
  • When engineered with fillers, they reduce stiction and friction improving device usability for surgeons
  • Ability to withstand repeated sterilization cycles for metal to plastic conversion applications
  • Custom compounding allows for properties such as electrical or thermal conductivity
  • Thin-wall molding and high-precision manufacturing are possible enabling complex, micromolded components
  • Overmolding of silicones and rubber compounds enables metal and plastic integration or soft-touch features to improve device ergonomics
  • The ability to rapidly prototype and iterate part designs accelerates time-to-market

High-Performance Plastic Materials

  • Implantable-grade polyetheretherketone (PEEK) offers exceptional mechanical properties similar to cortical bone, is biostable, radiolucent and FDA-cleared for multiple implant types
  • Barium sulfate (BaSO4) loaded compounds provide radiopaque contrast for imaging
  • Polyphenylsulphone (PPSU) has excellent toughness, steam sterilization stability greater than 1,000 cycles, high chemical resistance and excellent biocompatibility (ISO 10993)
  • Polyphenylene sulfide (PPS) is thermally and electrically conductive
  • Polysulfone (PSU) is tough and rigid, biostable, transparent and doesn’t absorb bodily fluids
  • Polyetherimide (PEI) exhibits high heat resistance and has strong mechanical performance
  • Polyurethanes (PU) are highly elastic and biostable with a history in lead insulation and vascular reconstruction
  • Nitinol for metal components combined with overmolded high-performance plastics
  • Custom compounds with high-filler content

Applications

PEEK

This material is biostable, radiolucent and has received FDA clearance for use in various implant types.

  • Spinal cages and interbody fusion devices
  • Orthopedic trauma fixation components
  • Cardiovascular implants
  • Dental implants
  • Connected drug delivery implants

PPSU

Favored for its toughness, high chemical resistance and steam sterilization stability.

  • Implantable housings
  • Transparent implant components
  • Limited geometry cardiology implants
  • Components requiring toughness

PSU

Offers a blend of toughness and rigidity, biostability, transparency and resistance to bodily fluid absorption.

  • Implantable components requiring rigidity and transparency
  • MRI compatible implant housings
  • Fluid handling implants

PU

These are highly elastic and biostable with a proven track record in applications like lead insulation and vascular reconstruction.

  • Vascular grafts
  • Pacemaker leads
  • Flexible, long term soft tissue contacting implants

PEI

Recognized for its high heat resistance and robust mechanical performance.

  • Implant instrument components
  • Implantable frames requiring stiffness

FAQs

  • What are thermoplastic molded parts?
    Thermoplastic molded components are a category of polymers known for their exceptional ability to maintain their mechanical, thermal and chemical properties when subjected to harsh operating conditions.
  • Which thermoplastics are commonly used for implantable devices?
    Common choices include implantable-grade PEEK, select polyurethanes, and other biostable high-performance polymers, depending on the design and regulatory requirements.
  • Can thermoplastics replace metal components in medical devices?
    Yes, replacing a metal component with a thermoplastic alternative can reduce the overall weight, improving the ergonomics of handheld finished medical devices and reducing the load of implantable components.
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