One unintended consequence of the COVID-19 pandemic has been to shine a light on just how vital plastics are when it comes to life-saving medical technologies. But this is nothing new –– advanced polymers have been playing a key role for decades in everything from implants, prostheses and medical housings to personal protective equipment (PPE), wearables and single-use devices such as syringes, blood bags and catheters.
Still, work continues apace by the industry’s chemists, scientists and engineers to further refine and enhance the properties of plastics materials for use in the healthcare space. The aim is to make such materials even safer and more biocompatible, chemical-resistant, sustainable and affordable.
Makers of plastic and rubber medical products also are investing heavily to keep pace with growing demand. Following is just a brief look at some recent developments.
In late June alone, Westfall Technik Inc. opened a completely refitted, 40,000-square-foot medical molding facility near Chicago with three Class 8-certified cleanrooms. Jabil Inc. broke ground on a $57 million, 160,000 square-foot healthcare injection molding facility in East Flat Rock, N.C., and Freudenberg Medical said it was adding 8,600 square feet to an existing facility in Alajuela, Costa Rica, to allow for an ISO Class 7 cleanroom for catheter manufacturing and assembly, molding, extrusion and packaging.
Additionally, Vernay Laboratories Inc., a flow-control specialist and precision rubber molder, earned ISO Class 8 cleanroom certification for the assembly and wash area at its Griffin, Ga., plant, and is investing to build a new, hardwall cleanroom at its facility in Asti, Italy, that will be completed by year’s end.
TPEs play medical role
Materials-wise, PVC remains the workhorse medical polymer, accounting for roughly one-quarter of all medical-plastic compounds, according to the Brussels-based PVCMed Alliance.
But more specialized polymers are making key advances. Teknor Apex Co. says tests have shown that its Medalist®-brand, medical-grade thermoplastic elastomers (TPEs) form a strong bond with copolyester, even after exposure to disinfecting chemicals. The tests were done using four clear grades of Eastman Chemical Co.’s Tritan resins.
Teknor Apex notes that overmolding TPEs onto copolyester offers medical device designers advantages by enabling the combination of hard and soft materials. Soft TPEs are desirable for gaskets, seals, grips, and soft-touch elements on rigid medical housings and other components.
Germany’s Kraiburg TPE GmbH & Co. KG also is responding to growing demand for extremely soft yet tough and durable TPEs. The firm recently introduced its Next Generation Supersoft TPEs, under the new name Thermolast® S. These materials are said to have a pleasant, soft surface similar to human skin, with a low hardness range of 30 to 50 Shore 00 or 45 to 70 VLRH (very low rubber hardness). The product’s good skin compatibility makes it highly suitable for paramedical applications such as orthopedic appliances that do not necessarily require medical approvals.
3D printing customized body parts
In England, researchers at the University of Nottingham’s Centre for Additive Manufacturing say they have discovered how to use a new 3D printing inkjet technology to tailor-make artificial body parts and other medical devices with built-in functionality. The result is better shape and durability while cutting the risk of bacterial infection.
PlasticsToday quoted research leader Dr. Yinfeng He as saying that “Most mass-produced medical devices fail to completely meet the unique and complex needs of their users. Similarly, single-material 3D printing methods have design limitations that cannot produce a bespoke device with multiple biological or mechanical functions.”
So, He said, the researchers applied a computer algorithm to design and manufacture, pixel by pixel, 3D-printed objects made up of two polymer materials of differing stiffnesses that also prevent the build-up of bacterial biofilm.
The team was able to create a new style of 3D printing with multi-materials that they claim are intrinsically bacteria-resistant and bio-functional. This would allow them to combat infection without the use of added antibiotic drugs. The researchers believe this technology will be particularly effective for producing highly customized, one-piece prosthetic limbs or joints to replace a lost finger or leg that can fit the patient perfectly. (See the complete findings as published in Advanced Science).
Antimicrobial copper compounds
Others are aiming to use material technology to reduce the chance of spreading infections. Tennessee compounder Techmer PM LLC just struck a deal to expand its long-standing partnership with Richmond, Va.-based Cupron Inc., regarding the manufacture and sale of compounds based on Cupron’s patented, copper-based antimicrobial technology.
Cupron formulates an active, oxidized copper ingredient in powder form, and Techmer PM encapsulates the product during its polymer compounding process. The ingredient helps to kill bacteria and imparts durable antimicrobial, anti-odor, and skin-enhancing properties to various finished products, to include sectors such as healthcare, transportation, recreational and consumer products, and retail and workplace environments. These materials can be used to enhance everything from PPE such as medical gowns and masks to high-touch hard surfaces such as countertops or bed rails.
COC resins for labware
Another resin used widely in medical applications is cyclic olefin copolymer (COC), a novel member of the polyolefin family that offers glass-like clarity and resists aggressive sterilization processes. AlphaGem Bio Inc., a San Francisco-area supplier of medical labware for liquid transfer handling, recently launched a polymerase chain reaction (PCR) plate made of TOPAS® COC from Polyplastics USA. The new plate for genomic testing uses that material because of its greater rigidity and heat stability compared to plastics such as polypropylene (PP) and polycarbonate (PC).
The injection-molded PCR plates are particularly suited for larger laboratories that use robotic handling for high-volume applications, according to AlphaGem Bio President Dale Taunk. “The use of cyclic olefin copolymer enables us to expand our product offering with a higher-performing option that meets automation needs,” he said. Germany-based TOPAS Advanced Polymers GmbH, a business unit of Polyplastics Co. Ltd., manufactures the COC materials.
The list of medical applications for a vast range of advanced polymers is large, diverse, and ever-growing, as plastics continue to rise to the challenge of meeting the demanding needs of the healthcare sector.
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Oh wow! You just made me realize that plastic-based devices are getting more and more popular in the medical world theses days, especially those created via 3D printing as well. The doctor in my neighborhood clinic plans to incorporate a more cost-effective mechanism to help her patients on a regular basis. I’ll certainly pass the information forward to her so she’ll be more encouraged to make the right purchase.