As medical device design evolves to provide ever-improving healthcare outcomes, manufacturers are partnering with full-service, experienced custom injection molders to gain increased design freedom and process efficiencies.Partnering with Kaysun — one of the few injection molders in the country to hold MedAccred Plastics accreditation — is a consistent value-add from part and tooling design through material selection and process control. It empowers many medical OEMs to address issues before they impact production or the bottom line.

Medical OEMs are tasked with providing consistent, high-performance solutions to the challenges posed by a variety of complex applications. Partnering with a custom injection molder that has the experience, knowledge, technical expertise, and certifications needed to adhere to the exacting standards of the medical industry is imperative.Not every molder is qualified, but those who are — like Kaysun — can move your business forward with confidence.

Polyamide-imide (PAI) is a tough, stiff, and incredibly durable plastic. This thermoplastic also has good chemical resistance and low thermal expansion and is rated for electrical applications. PAI has both high tensile and compressive strength, so it can adjust itself to forceful impacts. It has tight tolerances, such as resistance to fuels, solvents, and acids, which makes it a great candidate for use in the automotive industry. However, this thermoplastic can be expensive and difficult to process. It also expands when subjected to water, but it will remain dimensionally stable.

Polycarbonate (PC) is an astonishingly tough polymer with great manufacturability. It can also be transparent, which makes it an excellent high-impact-resistant alternative to glass. You likely encounter several PC applications in your daily life, from protective goggles and face shields to store-front windows and outdoor signs. In addition to its durability, it also boasts great heat and chemical resistance. PC can also be used as a glaze to protect structures from damage, such as government buildings, medical facilities, and transportation hubs. The downside is this polymer can be expensive to manufacture.

Acrylonitrile butadiene styrene (ABS) is a popular choice among manufacturers, as it boasts high impact resistance at a mid-range cost. This thermoplastic is well-suited for injection molding and bonds well with adhesives and coatings. Molders can also manipulate its final properties by heating it at different temperatures: a low temperature will yield more impact resistance, while a high temperature will increase its heat resistance. ABS is commonly used in automotive parts, children’s toys, and power tools. However, it’s important to understand that this polymer is not suitable for use with food and beverages.

Impact-resistant thermoplastics will ensure your parts remain structurally sound under pressure and are even great alternatives for metal. However, you need to ensure your parts are manufactured appropriately to fully benefit from the material’s impact resistance. At Midstate Mold, our team has several decades of experience prototyping impact-resistant parts and executing quality production. If you’re looking for an experienced injection molding manufacturer for your next project, contact us today.

Filed Under: Our blog Tagged With: ABS, acrylonitrile butadience styrene, HDPE, High-Density Polyethylene, impact-resistant plastics, PAI, PC, plastic injection molding, Polyamide-imide, Polycarbonate

Portable medical devices are a mainstay in hospitals, emergency vehicles, and outpatient environments. The devices must remain accurate and functional; however, drops, bumps, and excessive vibration are inevitable as equipment is transported from place to place.Overmolding is a proven solution for shock and vibration reduction, sound dampening, electrical insulation, improved chemical/UV resistance, effective oxygen and moisture barrier protection, and color infusion.

Kaysun is experienced with medical product design, production, and assembly. We are ISO 13485:2016 certified and MedAccred Plastics accredited.

When choosing a thermoplastic for your impact-resistant part, you want a material with great performance and longevity. The plastics listed above will stand the test of time, all while undergoing long periods of physical stress, but to find the right impact-resistant thermoplastic, you need to consider your part’s application. If you know your part needs to be strong yet transparent, polycarbonate is a preferred choice. If you need to it be safe around food, then avoid ABS. The best way to ensure you’re investing in the right material is to work with an experienced vendor who can give recommendations.

Many plastic parts – such as construction materials, outdoor equipment, and prosthetics – must withstand high, repetitious impact and bear significant loads of force. Not using a material that has proven toughness can run the risk of your part breaking, resulting in severe or sometimes life-threatening consequences. Choosing an impact-resistant polymer means finding the right balance between toughness and pliability. We’re here to help you by highlighting the top-impact resistant thermoplastic for injection molding.

The rapid advancement of the medical industry necessitates constant innovation and complexity in medical device design. Smaller sizes, more intricate geometries, progressive functionalities, and portability are among the greatest needs in today’s medical equipment — and among the biggest challenges for design and engineering teams.

High-density polyethylene (HDPE) offers incredible impact resistance and tensile strength. The molecules of this thermoplastic are so densely packed together that it enhances its toughness and rigidity. It also benefits from resistance to corrosion, abrasions, and chemicals. Though, it cannot withstand high-temperature environments. This is a low-cost material that is ideal for marine construction, outdoor equipment, and chemical tanks. Though under extreme pressure, cracks can eventually form, and you will need to work with an experienced molder due to its complex shrink rate.

Kaysun has carried the MedAccred Plastics accreditation since 2020, demonstrating our ongoing commitment to excellence and assuring medical OEMs of an unparalleled benchmark of production and quality standards.

Medical device performance is largely dependent on the characteristics of the materials used and application needs such as strength, flexibility, transparency, biocompatibility, safety-enhancing microbe resistance, and temperature and chemical resistance. With thousands of engineered materials to choose from, it's important to work with experts in medical device injection molding.

Leveraging the experience and knowledge of medical injection molders during the design phase of complex applications can help overcome the unique challenges of medical injection molding and improve outcomes.

“Kaysun exceeded our expectations in all areas. They made a complex, gigantic program easy from an engineering standpoint. Working with the Kaysun engineering team is like a hot knife through butter.”

Earning accreditation is a rigorous process, and only a small fraction of medical injection molding companies receive the distinction.

MedAccred is a Performance Review Institute medical device industry-managed supply chain oversight program dedicated to reducing patient safety risk. It focuses on critical manufacturing processes compliance and device quality and consistency.