Plastic Components for Medical Devices

Axenics recommends plastic components for medical devices because plastics are versatile, clean, sturdy and affordable. Three services especially valuable to the medical device manufacturing field are:

• Plastic manifold transportation systems
• Plastic tube bending
• Plastic pipe welding

Plastic manifold liquids and gas transportation systems

Plastic manifold transportation systems provide a continuous supply of chemicals for a variety of applications during the manufacturing process. These systems have a smaller footprint than other options due to built-in direct pathways, resulting in simple transport for liquids and gasses. The systems are versatile with the ability to expand using additional manifolds or transport lines. Manifold transportation systems also provide easy access for repairs – though repairs are uncommon for this type of system.

The manifolds Axenics produces for our customers are tested during each step of production to ensure a leak-tight performance. Fewer leak points also make manifolds a more-reliable transportation system for chemicals, liquids and gasses, as the risk of cross-contamination is lowered significantly.

Plastic manifold transportation systems are smaller than many other delivery systems with a lower part count, making them more affordable on the materials side. Plus, they generally have a faster production time than other delivery systems. One more plus is that the need for preventative maintenance is low for manifold delivery systems.

Manifolds can be used in the production of medical equipment including:

• Lab accessories
• Patient monitoring devices
• Diagnostic instruments
• Operational machinery 

Axenics works to provide a simplified, reliable system that delivers consistent, highly-repeatable performance, with the flexibility of subsystems that have the capability for multiple flow rates and pressures. Plastics can deliver those results, and some plastic options offer better insulation than metal manifolds.

FAQs about plastic manifold transportation systems

What materials are used in the production of plastic manifolds?

Plastic manifolds for medical devices are typically made from durable, high-quality plastics such as Polypropylene (PP) and Polyethylene (PE). These materials are chosen for their biocompatibility, chemical resistance and ability to meet stringent medical standards.

How does Axenics ensure the quality and leak-tight performance of their manifolds?

Axenics utilizes rigorous quality control measures, including precision welding techniques and pressure testing, to ensure that each plastic manifold is leak-tight and meets medical-grade standards. Additionally, we employ advanced fabrication methods to ensure consistency and reliability in every product.

What are the typical applications of plastic manifold systems in medical devices?

Plastic manifold systems are extensively used in medical devices for transporting gases and liquids. Common applications include IV infusion systems, dialysis machines, anesthesia equipment and various types of automated dispensing systems.

How do plastic manifold systems compare to traditional metal systems in terms of cost and durability?

Plastic manifold systems are generally more cost-effective than their metal counterparts, offering significant savings in material and production costs. They also provide excellent durability, being resistant to corrosion and chemical degradation, which is a critical factor in medical environments.

What maintenance is required for plastic manifold transportation systems?

Maintenance for plastic manifold systems is minimal, typically involving regular inspections to check for any signs of wear or damage. Cleaning protocols also need to be followed to ensure sanitary conditions, but overall, plastic manifolds require less maintenance than metal manifolds.

Can plastic manifolds be customized for specific medical device requirements?

Yes, plastic manifolds can be customized to meet specific medical device requirements. Axenics offers design support and fabrication services to tailor plastic manifolds to precise specifications, ensuring optimal performance and compatibility with your medical equipment.

Can plastic manifolds handle varying flow rates and pressures effectively?

Yes, plastic manifolds can handle varying flow rates and pressures effectively. They are designed to maintain integrity and performance under diverse operating conditions, ensuring reliable and consistent transport of fluids and gases.

Additional plastic manifold benefits

• High thermal mechanical strength: Some plastics are able to resist thermal degradation and maintain operating strength and rigidity in high temperatures.
• Good chemical resistance to acids, alkalis, greases and solvents, hydrogen peroxide, demineralised water and hot steam.
• Minimal outgassing (gas release within solid material) under vacuum: This is especially important in the medical device industry as maintaining a sterile environment is essential.
• Good creep resistance.
• Minimal thermal expansion.
• Good wear resistance.
• Good plasma resistance for reduced corrosion.

Plastic tube bending

Axenics bends plastic tubing using a variety of thermoplastics to create piping kits and tubing assemblies. We do a lot of work with Polytetrafluoroethylene (PTFE), a chemical-resistant plastic that is ideal for transporting potentially harmful liquids or gasses. Tube bending for delivery systems is also performed in-house on plastics such as:

• Polypropylene (PP)
• Polyvinyl chloride (PVC)
• Chlorinated polyvinyl chloride (CPVC)

We only use professionally cleaned and bagged raw tubing. Bending high-purity plastic tubes is a good option for production systems that transport corrosive liquids or volatile chemicals. Savvy manufacturers utilize plastic tubes for high-purity applications knowing there’s a smaller chance of contaminants getting into gas and liquid supplies versus some metal tubing systems. Metal tubes potentially suffer from flaking welds when high-pressure gas and liquids flow through them.

Axenics’ proprietary technique for plastic tube bending allows for a strong system free of kinks that works on plastic tubing from as thick as 2 inches down to 1/16th-inch. Through years of experimentation, Axenics’ technicians developed tube bending equipment and techniques with better performance than “standard tube bending.” These techniques and tooling options help achieve tighter tolerances and accomplish more modifications than conventional tooling and procedures typically allow. Custom tooling achieves the exact bend radius, angle and design required in a repeatable bending process. It’s also possible to bend any length of thermoplastic tubing.

Plastic tubing kits facilitate the movement of liquids and gasses from one area of a manufacturing system to another in one clean, clear shot. This expedites transport around plastic components for medical devices and other obstacles in a production system. End connections for tubing assemblies can simply mate with the connections already installed in an existing production space.

FAQs for plastic tube bending

How does Axenics’ proprietary technique for plastic tube bending differ from “standard tube bending?”

Axenics employs a unique, precise heat-controlled bending process that minimizes stress on the tubing material and ensures uniformity in bends. This method contrasts with standard tube bending techniques that may use mechanical force, which can introduce micro-cracks or uneven bends.

What are the benefits of using thermoplastics for tubing in medical devices?

Thermoplastics offer several advantages for medical device tubing, including high chemical resistance, flexibility, and ease of sterilization. They also provide excellent biocompatibility, making them ideal for direct patient contact.

How do plastic tubing systems reduce the risk of contaminants compared to metal tubing systems?

Plastic tubing systems are less prone to corrosion and do not require lubricants for bending, which reduces the risk of contaminants. Additionally, plastic materials can be smoother internally, reducing areas where bacteria might accumulate.

Can Axenics customize tube bending for specific medical device requirements?

Yes, Axenics offers customization for tube bending to meet the unique requirements of different medical devices. This includes tailoring the bend radius, angle and design to fit seamlessly into the client’s applications.

What are the limitations, if any, of using plastic tube bending in high-pressure applications?

While plastic tubing offers many benefits, it may not be suitable for very high-pressure applications compared to metal tubing. The suitability would depend on the specific type of plastic used, its wall thickness, and the application’s pressure requirements.

What criteria are used to determine the ideal bend radius, angle, and design for plastic tubing?

Criteria include the tubing material’s flexibility, the required flow rate, the space constraints of the medical device and the need to maintain structural integrity without kinking or collapsing the tube.

Can Axenics’ plastic tube bending techniques be applied to other industries besides medical devices?

Absolutely. Axenics’ plastic tube bending techniques can be adapted for various industries, including pharmaceuticals, biotechnology and industrial applications, where precise and reliable fluid and gas transportation systems are needed.

How does the inspection and quality control process work for bent plastic tubes in medical devices?

At Axenics, the inspection and quality control process includes rigorous testing for defects, measurement verification to ensure adherence to design specifications and checks for structural integrity. Each tube undergoes visual and dimensional inspections to guarantee it meets the highest quality standards.

Additional plastic tube benefits

• Bent plastic tubing holds up well against vibrations when placed into large machinery. Vibration fatigue and failure can be a problem with some moving mechanical systems and equipment.
• The efficiency of plastic bending increases a manufacturer’s production capabilities without raising costs since there is less raw material required for plastic fabrication and fewer – if not zero – fittings required.
• Precision bending on plastic tubing decreases the likelihood of potential leaks via welded joints.
• Bent plastic tubes generally integrate into a manufacturer’s existing machinery without compromising the integrity of either the tubes or systems.

Plastic welding

One of the biggest challenges medical device manufacturers face is creating complex components with miniature segments through which liquids and gasses can easily pass. Plastic welding provides a solution for manufacturing plastic components for medical devices with safety in mind, while also ensuring a longer lifespan of the product. Plastic welding is used to: 

• Construct patient-monitoring devices
• Produce diagnostic instruments 
• Create components for machinery used in life-saving operations

Plastic welding is often a faster and simpler fabrication process versus welding with metals because plastics are generally lighter in weight than many metals. Plastics are also a wise choice for maintaining the safety and reliability of your end product as they are more chemically resistant than most metals.

The proprietary welding method Axenics employs is also highly repeatable, which is helpful as the demand for “more and faster” increases. Axenics’ method of welding plastics does not alter the chemical makeup of the piping and does not compromise the piping in any way. This remains an important distinction that attracts fabrication engineers, as the welded plastic piping kits provide a flawless and consistent transportation system of potentially dangerous and harmful chemicals and gasses.

Plastic piping kits provide a seamless transition when adding to existing chemical and liquid delivery systems. The kits ship with end connections that plug right into mating units on the customer’s end. Or, a series of piping systems can be mounted together for customers’ fluid line systems. PFA is a resilient and stable plastic and has the ability to withstand exposure to harsh chemicals. It’s a versatile plastic that seamlessly fits into many customers’ existing systems.

FAQs for plastic welding

How does plastic welding compare to other methods of joining plastic components for medical devices?

Plastic welding offers a seamless and robust connection compared to adhesive bonding or mechanical fastening. It eliminates the need for additional materials like screws or glue, providing a sterile, contamination-free solution ideal for medical applications.

How does the chemical resistance of plastics used in welding contribute to the longevity of medical devices?

The chemical resistance of plastics like PFA, PP, and PE ensures that welded plastic components for medical devices can endure sterilization processes and exposure to various chemicals without degrading. This resilience contributes significantly to the longevity and reliability of medical devices.

What safety measures are taken to ensure the reliability of plastic welded medical components?

Axenics implements rigorous quality control measures including visual inspections, pressure testing, and non-destructive testing (NDT) to ensure that each welded component meets the highest safety and reliability standards.

Can plastic welded components be customized for specific medical applications?

Yes, plastic welded plastic components for medical devices can be tailored to fit specific medical needs. Axenics offers custom design services to create plastic components for medical devices that match exact specifications for various medical devices, ensuring optimal functionality and performance.

How does the repeatability of Axenics’ plastic welding method benefit the manufacturing process?

The repeatability of Axenics’ plastic welding methods ensures consistent quality and performance across large production runs, which is crucial for maintaining uniformity and reliability in medical devices.

What makes PFA a preferable choice for plastic welding in the medical industry?

Perfluoroalkoxy (PFA) is favored in the medical industry for its superior chemical resistance, high purity, and excellent thermal stability. These properties make it ideal for producing plastic components for medical devices that must withstand rigorous sterilization and harsh chemical environments.

How are plastic piping kits from Axenics integrated into existing medical systems?

Axenics’ plastic piping kits are designed for easy integration. They are pre-engineered to match existing medical system specifications, ensuring a seamless fit and reducing installation time and complexity.

Are there any limitations or challenges associated with plastic welding for medical devices?

While plastic welding offers numerous benefits, challenges such as material compatibility, proper alignment and welding parameters need to be meticulously managed. Axenics’ expertise in these areas ensures that these challenges are effectively addressed.

What are the environmental benefits of using plastic over metal in medical device manufacturing?

Plastics offer environmental advantages over metals, including a lower carbon footprint and recyclability. They also reduce the weight of medical devices, leading to energy savings in transportation and handling.

How does Axenics ensure the consistency and quality of their plastic welding?

Axenics guarantees consistency and quality through advanced automation, strict adherence to welding protocols, continuous monitoring and comprehensive testing throughout the production process.

Additional plastic welding benefits

• Plastic welds have a strong resistance to acids, alkalis, greases and solvents, hydrogen peroxide, demineralized water and hot steam.
• Plastic welds offer a minimal release of gas under vacuum, which helps maintain a sterile environment.
• Plastic welds have a strong plasma resistance reducing the possibility of corrosion.
• Plastic welds resist thermal degradation and maintain a high operating strength and rigidity in high temperatures.
• Plastic welds offer the benefits of good creep resistance, minimal thermal expansion and good wear resistance.
• Plastic welding provides a simplified system that delivers a consistent, highly-repeatable performance. There is also the flexibility of easily adding thermoplastic sub-systems that provide multiple flow rates and pressures.

Cleanliness is also key

Axenics takes cleanliness extremely seriously. When creating plastic components for medical devices, we utilize a cleanroom in order to keep any particles or contamination from ending up in your production. It only takes a miniscule piece of dust to severely damage a component. It’s like tossing a big, filthy wrench into the gears.

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