Originally Published MPMN January 2005
Outsourcing Outlook
Company Molds Handles for Medical Device OEMs
Manufacturer Expands Capabilities to Include Thermoformed 3-D Products
A manufacturer creates ergonomic silicone handles for use on a variety of medical devices. The handles are produced using a proprietary process that overmolds the silicone onto stainless-steel, aluminum, and high-performance plastic cores. The material used for the handles is a custom-blended formulation allowing for specific hardness, texture, and color requirements. No-play ratcheting drivers, torque-limiting and torque-measuring instruments, and standard shaft quick-locking connectors are among the instruments that use the handles. The company also offers custom instrument-handle development services. Rapid prototyping and on-line design reviews with customers hasten the development process on new handle shapes. Gauthier Biomedical, Grafton, WI www.gauthierbiomedical.com
Molder Provides Low-Volume Production Programs 
Economical low-volume production programs for custom enclosures and bezels are available. Using aluminum and prehardened steel molds, the company produces molded enclosures that meet exact design specifications. Many materials and colors are available. Because there are no minimums on production orders, the service can be used for initial launches and into production. The tooling is guaranteed into the hundreds of thousands of pieces. Mold Threads Inc., Branford, CT www.moldthreads.com
Micromold Manufacturer Expands Capabilities
A high-precision micromold manufacturer has added microinjection molding capabilities, as well as turnkey micromolding systems. The company offers precision components with tight tolerances, including 0.5 ¥ 50-µm microfluidic slots, slots in sensors as small as 0.002 in., nozzle orifices as small as 0.0027 in. diam, and cannula and medical pouches with walls that are 0.0015-in. thick. By adding custom micromolding and custom-built turnkey micromolding systems to its capabilities, the company can provide single-source, plug-and-play solutions to medical device OEMs. Complex microscopic parts or microscopic design features on larger parts in devices such as catheters, microfluidic nozzles and chips, MEMS and microsensors, resorbable implants, electronics, and tiny industrial pumping mechanisms can be produced quickly. Miniature Tool & Die Inc., Charlton, MA www.miniaturetool.com
Engineered Resins and Insert Molding Are Among Company’s Specialties
A contract firm’s injection molding division offers custom design, tooling, and injection and insert molding of products for the medical device industry. Small- to medium-size runs and detailed insert molding are among the company’s specialties. Its in-house design department uses highly advanced three-dimensional software, a fully equipped mold-making shop, and current injection molding technology. Various engineering polymers are used, from thermoplastic elastomers to reinforced or filled resins. Shot sizes range from 1¼10 of a gram up to 80 oz. Hot stamping, ultrasonic welding, and packaging services are also available. Plastics One Inc., Roanoke, VA www.plastics1.com
Molding Facility Uses Aluminum Tooling
A manufacturing company specializes in custom injection molding of parts for use in a variety of applications. Its CAD/CAM tool room includes CNC, EDM, and conventional machinery. In addition to standard steel tooling, low-cost aluminum tooling is also offered. Engineers are available to assist customers with improving product design and function. ACI Medical Inc., San Marcos, CA
www.acimedical.com
Tooling and Molding Process Supports Rapid Device Development
Injection molding tooling can be produced in 10 working days by a parts manufacturer. Quick turnaround times allow engineers to develop concepts and, once proven, proceed immediately to full production. The company’s molding process is capable of using any injection-moldable material, such as commodity resins, Ultem, and PEEK. The firm produces parts for medical device OEMs. Advanced Technology, Corona, CAwww.adv-tec.net
Contractor Offers Cleanroom Injection Molding 
A full-service contract manufacturer offers high-precision custom molding in a certified Class 100,000 cleanroom. A variety of Class VI medical-grade, sterilizable materials provide thermal performance, strength, and durability. The company’s molding facility utilizes high-speed material-handling equipment and closed-loop processes to ensure products are molded in a controlled environment. Process controls are in place to allow for tight tolerances in a fully automatic cycle. Services include mold-tool design, build, and prototyping in conjunction with injection molding to maximize mold performance. Advanced Scientifics Inc., Millersburg, PA www.advancedscientifics.com
Custom Molder Produces Parts in Controlled Environments
A tubing supplier has introduced a total intermittent extrusion (TIE) process, enabling the continuous extrusion of rigid-to-soft catheters without bonding. Engineers can design catheters with a smooth transition point between polymers with hardness levels ranging from 75 D to 80 A. According to the company, TIE reduces breakage at the rigid-to-soft point compared with standard bonding technology. Suitable for use in applications that require a stiff shaft and flexible tip, the tubing is used in urology, radiology, neurology, and cardiology applications. TIE tubing is also available in multilumen form, composed of thermoplastic medical polymers. The level of radiopacifier can be customized to illuminate specific sections of tubing. Putnam Plastics Corp., Dayville, CT www.putnamplastics.com
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