Prototyping for Manufacturability – Medical Product Outsourcing

Avalon’s proof of concept and prototyping options are discussed within the article:

Avalon Laboratories LLC is a medical device manufacturer in Rancho Dominguez, Calif., that makes surgical and minimally invasive devices. The company provides both proof of concept and rapid prototyping to its clients. The company’s expertise lies in its polymer solution casting technology, which uses liquid polymers throughout the manufacturing process resulting in specialized designs unobtainable by extrusion technology. This technology offers the ability to add multiple components, varying wall thickness or diameter along the length of the device. With polymer solution casting the process provides the ability to embed components in virtually any configuration. Because this process is unique to Avalon, proof-of-concept prototyping is one of the company’s most important methods of demonstrating to clients exactly how this manufacturing process will benefit their device.”

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Avalon Polymer Solution Casting Medical Product Outsourcing Article

Polymer Solution Casting

With most co-extrusion technologies, bondable materials are located either on the OD or ID for ease of assembly of complex medical devices. It’s a multi-step process—depending on the complexity of the part or product and performance expectations, some extruders provide up to three or four materials on an extrusion run, followed by multiple pass options. Many of these materials are not ideally compatible for bonding and require a tie-layer to hold them together, or a multiple-step lamination process.

An alternative to co-extrusion is polymer solution casting, which utilizes a liquid polymer layering process to create an “all in one” continuous piece with no bonded joints and increased design flexibility. Polymer solution casting provides the ability to add multiple components and varying wall thicknesses or diameters along the length of the device. It also is possible to embed components in virtually any configuration—a production capability that expands the range of design possibilities for medical device engineers.

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Polymer Solution Casting Thin Layering Process Overcomes Multilayer Tubing Challenges

As tubing designs become more complex, medical tubing production has had to adapt to accomplish all of the requirements and typically with several different manufacturing steps and bonds necessary. To meet performance needs extrusion technology utilizes multi-layer extrusion. Multi-layer technology is used to improve functionality or to combine a weldable OD material with additional materials that add performance properties.

Avalon’s polymer solution casting technology utilizes a liquid polymer layering process to create an all in one piece continuous construction with no bonded joints and increased design flexibility. The polymer solution casting seamlessly offers the ability to add multiple components, varying wall thickness or diameter along the length of the device. It is the ultimate multi-layering approach offering pinpoint delivery performance where needed.

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