For more intricate detailing and a less expensive alternative to polyvinyl chloride injection molding, we use pressure forming. Like vacuum forming, we fit heated PVC around a tool, but then, we use highly pressurized air to blast the plastic, pressing it firmly against the tool, creating sharp edges and corners and high levels of detail for construction materials and other products.

Meeting stringent regulatory requirements is a non-negotiable in the medical device industry. Injection molding excels in this regard. The ability to use FDA-approved materials and consistently produce parts that meet these standards ensures compliance from the outset.

Polyvinyl chloride is a thermoplastic polymer that can be heated and shaped for a multitude of materials. PVC in its pure state is highly rigid and brittle, but by adding plasticizers or phthalates, it can be softened, often taking the place of rubber, or blended with cotton to make canvas. We use a variety of PVC based materials to meet the needs of our customers.

Process Validation as defined by the FDA is “The collection and evaluation of data, from the process design stage throughout production, which establishes scientific evidence that a process is capable of consistently delivering quality products.”

Injection molded parts can undergo a variety of post-processing operations, such as assembly, machining, laser marking, pad printing or surface finishing, to meet the exact requirements of the medical device.

Injection molding allows medical design engineers the freedom to design complex or intricate parts, a vast selection of suitable materials and the consistency to produce both low and high volumes of devices.

PVC is highly durable and offers excellent resistance chemical damage, water and moisture, and abrasion. Because it’s so versatile and can be blended with a variety of additives to change its properties from extremely rigid to soft and flexible, it’s commonly used in thermoforming, while its dimensional stability and low melting point makes it ideal for injection molding.

For smaller plastic components and parts, or parts that require high levels of detail or varying thickness, we use polyvinyl chloride injection molding. This is a more intensive method of plastic manufacturing because it requires designing a double-sided mold made from steel, aluminum, or copper alloy. Then, the PVC is melted to a liquid state and injected into the mold, creating a detailed, highly accurate finished shape that is either ready for painting or customization or to be packaged and sent to our customers.

With streamlined production processes, injection molding can significantly reduce time-to-market for medical devices. This is crucial in a rapidly evolving industry where innovations can make a significant impact on patient care and outcomes.

We’re proud to be a leader in polyvinyl chloride based material manufacturing, known for providing competitive pricing and fast lead times. We work with a variety of industries, creating reliable, long-lasting plastics for businesses in North Carolina, South Carolina, Pennsylvania, Maryland, Tennessee, Georgia, and Virginia.

The high initial tooling costs can be a barrier to entry for some manufacturers. However, once the molds are in place, injection molding is incredibly cost-effective for large production runs. The ability to produce a large number of parts in a short time reduces unit costs significantly, making it an ideal choice for mass production.

Vacuum forming is the most basic method of polyvinyl chloride thermoforming in which the PVC is heated to a malleable state, then fitted to a custom tool. Then, a highly powered vacuum is fitted between the tool and plastic, removing all air from between the two and pulling it snugly against the tool, creating an accurate shape. This method is best for larger products where high levels of detail or sharply defined corners aren’t necessary. In fact, polyvinyl chloride vacuum forming is used for things like bathtubs and shower trays.

Many medical devices must be in direct contact with the human body. Injection molding allows manufacturers to choose biocompatible materials, ensuring patient safety. These materials can be sterilized without affecting their properties, making them suitable for a wide range of medical applications.

Since 1988, Advanced Plastiform, Inc., has been providing superior custom plastic molding and fabrication services to companies in North Carolina, South Carolina, Maryland, Georgia and Pennsylvania. Contact us to make an appointment Mon-Fri 8-5.

The injection molding process generates minimal material waste compared to other manufacturing methods. This not only contributes to cost savings but also aligns with the increasing focus on sustainable and environmentally friendly manufacturing practices.

Polyvinyl chloride is most widely known for the rigid PVC pipe used in plumbing and water infrastructure systems. To create pipes and other hollow tubes such as air ducts, we use twin sheet forming. Twin sheet forming is the most complex polyvinyl chloride thermoforming method because it requires two sheets of plastic to be heated and shaped at the same time, then fitted and fused together. There is no room for error as the plastic must be matched precisely at pressed points in order to join together properly.

At PTI, we have over 16,000 square feet of ISO Class 8 cleanroom space that we utilize in our injection molding process to ensure as little contamination as possible.  We adhere to strict protocols that meet the demands the medical industry requiring ISO 14644 Cleanroom specifications, including bioburden and electrostatic discharge (ESD).

One of the most significant advantages of injection molding is its design flexibility. Engineers can create complex, customized components with minimal tooling changes. This adaptability is essential in a field where the demand for innovative and unique medical devices is ever-expanding.

At Advanced Plastiform, Inc., we work with companies across the Southeast and Mid-Atlantic states, designing and manufacturing custom plastics for all types of use - from car bumpers and trunk liners to medical trays and packaging. In order to provide the best outcome for each individual product, we have a wide variety of thermoplastic materials available to use, but one common plastic we use is polyvinyl chloride, more commonly known as PVC. In fact, PVC based materials are some of the most commonly used plastics in the world.

To create large plastic products and components, we often use polyvinyl chloride thermoforming, which involves heating the PVC to where it’s soft and flexible, then fitting it around a custom tool to create the ideal shape and design. Both affordable and efficient, our polyvinyl chloride manufacturing company uses three different types of PVC thermoforming methods to ensure the best results while providing lower costs and faster lead times to our customers.

Injection molding produces parts with a high level of structural integrity, ensuring they can withstand the rigors of their intended application. These parts are less prone to defects and offer superior performance over their lifecycle.

Injection molding for medical devices represents the perfect synergy of precision engineering and advanced manufacturing technology. Its benefits, from precision and consistency to cost-efficiency and regulatory compliance, make it a top choice for design engineers and medical device manufacturers. The process empowers engineers to innovate, create intricate components, and bring lifesaving devices to market faster than ever before. The future of medical device manufacturing is being molded with precision, and injection molding is at the forefront of this revolution.

We have been serving the medical industry for nearly 40 years, specializing in handling complex, multi-part programs and medical device molding for a variety of customers. Our direct contact with doctors and other medical professionals gives us insight into their needs and helps define and assist with final product solutions.

Injection molding offers unmatched precision and consistency in the production of medical device components. The process allows for intricate designs and tight tolerances, ensuring that each part is identical to the next. This uniformity is crucial in the medical field, where reliability and precision are paramount.

Furthermore, we have over 5,000 square feet of controlled environment space.  This segregated area is temperature controlled and pressurized, and can accommodate part decorating, assembly and packaging needs.

Having served the medical industry for nearly 40 years, we understand medical device manufacturing.   Plastic Injection Molding remains one of the best manufacturing methods for achieving precision and cost-efficiency as well as maintaining patient safety.

Process validation is the best way to ensure the production of safe parts, to reduce rejection rates, to prevent part failures in the field and to ensure the part meets with application, specification and regulatory obligations.

Injection molding is scalable, which means it can cater to a variety of production volumes, from small-scale prototypes to mass production. This scalability offers manufacturers the flexibility to meet different market demands.

Mold Design is a crucial step in the injection molding process.  Once you’ve finalized your part in CAD software for fit and function, it must then be transformed into a design for molding to ensure the capture of all the specified details.  In some cases, certain features of the part design may not be manufacturable via the injection molding process.

Both rigid PVC and flexible PVC have a wide variety of uses. While most people equate it with PVC pipe and other construction materials, it’s also the plastic used in vinyl siding, window frames, and roof lining. In fact, it’s used in virtually every industry to make things like:

At PTI, we collaborate with you to achieve the best possible design for manufacturability.  In fact, we have a FREE guide to help you with this.

Some of the most common materials used in medical devices are: Polypropylene, ABS, Polyurethane, Polyvinylchloride, Polycarbonate, Polystyrene, Polysulfone, Acetal and Polyethylene.

In many cases, our medical device customers look to process validation to ensure quality parts.  After all, patients lives depend on PTI to deliver high quality parts each and every time.

PTI Engineered Plastics provides medical device manufacturers with full-service advanced product development delivered in a compressed timeframe. With superior design for manufacturability, tooling, and molding capabilities, PTI turns product visions into reality and gets your product to market first.

Enjoy precision and durability you can trust with our PVC manufacturing expertise. Partner with our leading industry professionals in high-quality custom plastics.

Careful selection of materials is extremely important within the medical industry. Materials must meet FDA and other regulatory standards, ensuring patient safety, biocompatibility, sterilizability and durability.  As Injection molding allows for a vast selection of both thermoplastic and thermoset materials to choose from, there is certain to be a material suitable for just about any application.