Injection Molding & Rapid Prototyping for Medical Devices Manufacturing

Medical Injection Molding is an injection molding process that may be used to make medical devices such as syringes, catheters, and surgical instruments. The process involves injecting a fluid (most of the time, the polymer) into a part of the device, which is heated at a high temperature. This causes the polymer to melt and flow into depressions on the surface of the tool generated by mechanical milling. The melted material is then drawn out by vacuum and air pressure through one or more nozzles at different locations, depending on application requirements.

Medical Device Injection Molding can incorporate features of other stamping processes such as wire punch technology, blow molding or spray moulding, and capillary action-based pharmaceutical processing. Once the polymer has been injected into the tool, it is drawn out by a vacuum. This can be done through a single nozzle which is considered to be single-pass injection molding, or through multiple nozzles, which is termed multiple pass injection molding.

Single-pass injection molding is typically used in applications where small quantities are required with high dimensional accuracy and where cost reduction of device fabrication is critical. If a large number of parts are required, multiple pass injection molding would be more cost-effective since it minimizes setup time and also has a higher throughput capacity. For example, for plastic parts in the medical device industry, up to tens of thousands of parts can be produced at once.

Rapid Prototyping

Rapid Prototyping is the process of producing functional models from a digital file in order to demonstrate functionality and create a functional design, often at a reduced price. The speed at which these prototypes can be produced is dependent on many factors like the experience of the person who is making the prototype, the experience with 3D printing, and also if it is an old maker or not. The cost of Prototyping is often dependent on how many parts are needed as each part will require many steps to complete the parts. Each of the steps will have a cost associated with it. Cost can be reduced by 3D printing, but only if there is at least one person that has created a prototype before or has experience in doing so.

The most common rapid prototyping methods are,

● Fused Deposition Modeling (FDM)

● Selective Laser Sintering (SLS)

● Stereolithography (SLA)

Rapid Prototyping uses technology to produce real objects from 3D data, which means that physical parts can be produced from CAD designs, allowing for better design verification through testing and virtual functionality within products.

Rapid Prototyping is widely used for the manufacturing of medical device components, in particular for complex geometries. It is considered the best way to ensure that the geometry of the device will lead to the desired function. The main advantage is the ability to produce a limited number of devices at a reasonable price. All manufacturing methods involve creating a solid model from several 2D cross-sections but involve different techniques for creating these cross-sections and therefore produce different results.

When looking at medical devices, one will find there are a lot of variables that can go into producing any specific medical device as there are many requirements for medical devices when compared with other devices or machines. This is because the function of the device is based on a lot of different variables, and the anatomy of this particular patient or patient group can change with each patient suffering from a specific disease or illness. This will make finding the optimal design for such a device-dependent on the needs of that specific group.

There are several suggestions as to how to approach this problem, and anyone who is in charge of creating such devices should consider how it may go about creating these devices for any patients that will use it. Most people would say it would be too expensive to do testing on each individual patient when developing such devices, so they would look at ways to speed up their prototyping process.

Applications of Medical Device Injection Molding

Beakers, Test Tubes, and Other Containers: For bio-analytical procedures, glass beakers, test tubes, and similar containers are used to hold samples. Plastic containers, such as PET or plastic vials, are usually not suitable for use with samples because they do not allow the necessary air circulation to keep samples at a standard temperature. Medical device makers usually take advantage of these containers and use injection molding techniques in order to produce the necessary containers in bulk quantities.

Housings and Casings for Medical and Laboratory Equipment: Some medical devices and laboratory equipment have housings that have a screen or barrier in order to prevent contamination from a surface. These barriers are used for masks, gloves, protective covers for needles and syringes, incubators, pumping parts, and test tubes. For medical device makers, these types of components are often modeled using CAD software and then 3D printed in order to produce these products.

Surgical Equipment and Components: Medical device makers often use injection molding techniques in order to produce surgical devices such as surgical scalpels, forceps, or other devices used in the operating room. Injection molding is an effective way of producing a large volume of high-quality surgical components at a low cost. The main advantages of using injection molding for surgical devices are that the process is fast, low cost, and produces high-quality products.

Drug Delivery Equipment and Components: Medical device makers also use injection molding techniques to produce delivery devices and components used in drug delivery equipment. Examples of drug delivery components that can be made with injection molding include syringes, vial caps, and Luer fittings. These components are often produced with plastic materials that are used to create the air-tight seal necessary for the proper function of the equipment. Injection molding is a fast and cost-effective way for medical device makers to produce various types of drug delivery equipment so they can design and manufacture these devices with no delays or financial issues.

Materials for Injection Molding in Medical Devices

There are different types of injection molding materials that can be used in medical devices. Some of the most common include:

● PC or ABS – Used in handles and housings where high-temperature resistance is important    

● PBT: Provides good strength and toughness at a low cost      

● Polyethylene (PE): Also provides good strength but is slightly more brittle than PBT      

● Ultra High Molecular Weight Polyethylene (UHMW): Used to create high-performance parts such as vial caps, syringe plungers, etc. Also very strong and durable compared with other materials. It can only be used for thin-walled parts due to insufficient stiffness for larger applications.


Injection molding is a versatile manufacturing process that is extremely effective for producing medical devices. It is an outstanding choice for anyone looking to make metal parts because it is not only fast but also produces high-quality products with standardized standards. In addition, injection molding can be used with virtually any type of plastic or rubber in order to produce custom parts that are ideal for use in medical devices. By utilizing injection molding techniques, medical device manufacturers can save time and money while maintaining the highest quality production standards possible.

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