Medical Device Custom Injection Molding

Making medical devices requires extreme precision, top-notch reliability, and strict rules to follow. Custom injection molding is a key part of this process because it helps create parts that fit the special needs of medical devices—like being safe for the body, having complex shapes, or staying clean during production. But not all custom injection molding services can meet these high standards.

At Senses, we know how important it is to make medical parts that work perfectly and keep people safe. From the first idea to the final product, Senses is here to help you every step of the way. Whether you need just a few test pieces or a big production run, our team works closely with you to make sure everything matches your needs exactly.

Why Choose Custom Injection Molding for Medical Devices?

If you’re making medical devices, picking the right way to produce parts is super important. Custom injection molding is a great option because it’s perfect for the special needs of medical devices. Here’s why it works so well:

1. Makes Parts Super Accurate

Medical devices need parts that are exactly right—no mistakes allowed. Custom injection molding creates parts with really precise shapes and sizes every single time. This makes sure your devices work perfectly and keep people safe.

2. Works with Special Materials

Custom injection molding can use all kinds of materials, like PEEK, Ultem, and LSR. These materials are made just for medical stuff—they’re safe for the body, strong, and can handle being sterilized over and over.

3. Saves Money in the Long Run

At first, setting up for custom injection molding might cost more, but when you’re making lots of parts, it’s actually cheaper. It uses less material and doesn’t need as much manual labor, so you save money while making tons of parts.

4. Can Be Customized Easily

Whether you need just a few parts for testing or thousands for production, custom injection molding can adjust to what you need. You can also change the design whenever you want, so your parts always fit your device perfectly.

5. Follows All the Rules

The medical world has lots of strict rules, and following them is a must. Companies like Senses make sure everything they do meets those rules, like ISO 13485 and FDA standards. This means your devices will pass inspections and be safe to use.

6. Helps You Test Quickly

When you’re designing a new device, you’ll probably want to try out different versions. Custom injection molding lets you make quick prototypes so you can test and improve your design faster.

7. Grows with Your Business

As your company gets bigger, you’ll need to make more parts. Custom injection molding can handle that growth easily, going from small batches to big productions without any problems.

8. Keeps Things Clean

A lot of medical devices need to be made in super clean environments. Custom injection molding can happen in cleanrooms, which are special rooms that keep everything sterile. This is really important for devices used in hospitals or clinics.

At Senses, we help you turn your ideas into real devices that meet all the tough medical standards.

Material Expertise for Medical Applications

When it comes to medical devices, the materials used are just as important as the design itself. The right material ensures safety, durability, and functionality—key factors in creating reliable medical components. At Senses, we specialize in working with a variety of high-performance materials tailored specifically for medical applications. Here’s an overview of the materials we use and why they’re ideal for your needs:

1. PEEK (Polyether Ether Ketone)

• Why it’s great: PEEK is incredibly strong, lightweight, and resistant to heat and chemicals. It’s also biocompatible, meaning it won’t cause adverse reactions when in contact with the body.
• Common uses:
  • Implants (e.g., spinal cages, joint replacements)
  • Surgical instruments
• Benefits:
  • Excellent wear resistance
  • High strength-to-weight ratio
  • Suitable for sterilization methods like autoclaving

2. Ultem (Polyetherimide)

• Why it’s great: Ultem offers excellent thermal stability, electrical insulation, and chemical resistance. Its biocompatibility makes it perfect for long-term medical use.
• Common uses:
  • Diagnostic equipment housings
  • Components for drug delivery systems
• Benefits:
  • Can withstand high temperatures
  • Lightweight yet durable
  • Ideal for devices requiring transparency or rigidity

3. LSR (Liquid Silicone Rubber)

• Why it’s great: LSR is soft, flexible, and highly biocompatible. It’s also resistant to extreme temperatures and can be easily sterilized.
• Common uses:
  • Seals and gaskets
  • Drug delivery systems (e.g., syringes, catheters)
  • Patient-worn devices
• Benefits:
  • Exceptional flexibility and elasticity
  • Non-toxic and hypoallergenic
  • Perfect for parts that need to maintain shape under pressure

4. Polycarbonate (PC)

• Why it’s great: Polycarbonate is transparent, impact-resistant, and easy to mold into complex shapes. It’s often used where visibility and strength are required.
• Common uses:
  • Blood glucose monitors
  • Imaging device housings
• Benefits:
  • High optical clarity
  • Strong and shatterproof
  • Compatible with various sterilization techniques

5. ABS (Acrylonitrile Butadiene Styrene)

• Why it’s great: ABS is tough, versatile, and easy to color or finish. It’s commonly used for exterior components due to its durability and aesthetic appeal.
• Common uses:
  • Device casings
  • Handles for surgical tools
• Benefits:
  • Good impact resistance
  • Easy to process and customize
  • Cost-effective for non-critical applications

6. TPE (Thermoplastic Elastomers)

• Why it’s great: TPE combines the best properties of rubber and plastic, offering flexibility, softness, and durability. It’s often used for ergonomic grips and seals.
• Common uses:
  • Grips for handheld devices
  • Tubing connectors
• Benefits:
  • Comfortable to touch
  • Resistant to oils and chemicals
  • Easily recyclable

How We Choose the Right Material for You

At Senses, we don’t just pick any material—we carefully match each one to your specific application. Factors like part function, environmental exposure, sterilization requirements, and cost all play a role in our decision-making process. Our team works closely with you to ensure the chosen material aligns perfectly with your project goals.

Why Trust Us with Your Material Needs?

Our expertise in medical-grade materials means you get components that are safe, functional, and compliant with industry standards. Whether you need something rigid, flexible, transparent, or biocompatible, we’ve got the knowledge and experience to deliver exactly what you need.

Let us help you find the perfect material for your next medical device project!

At Senses, we specialize in medical device custom injection molding, offering tailored solutions that meet the unique demands of the healthcare industry. Whether you need small-batch prototypes or large-scale production runs, our medical device custom injection molding services are designed to deliver consistent quality while maintaining flexibility to adapt to your evolving needs.