Medical Plastics Under the Microscope at SPE/MPD MiniTecMedical Plastics Under the Microscope at SPE/MPD MiniTec

The medical plastics industry continues to advance on a global scale with innovative materials, processing methods, and designs. Regulations and sustainability initiatives also continue to expand, making it vital for stakeholders to stay abreast of industry developments. Good news: You can start the new year with a deep dive into all aspects of medical plastics at the two-day SPE/MPD MiniTec conference in February.

The Medical Plastics Division of the Society of Plastics Engineers (SPE) will bring two full days of education and networking for industry professionals on Feb. 3 and 4, 2025, to the Anaheim Convention Center in Anaheim, CA, alongside the MD&M West trade show and conference, which runs from Feb. 4 to 6.

Wide ranging topics to be discussed during the event will include advanced polymer materials, additive manufacturing, biopharmaceuticals, telehealth and telemedicine, interactions with sterilization methods, and much more. See below for descriptions of spotlighted sessions. A full conference schedule with session dates and times will soon be available on the conference website.

Antimicrobials In medical plastics

Despite the many tools available today to aid infection prevention and support sterile environments, the growth of microorganisms on various surface types remains a major problem. Without proper mitigation, microorganisms can affect the useful life of many products, including diminished physical properties, aesthetics, and odor. Within those medical settings where the existence or non-existence of microbes is most critical, antimicrobials that are built into materials have been proven to help lower surface-level bioburden.

During this session, the utilization of common antimicrobials in plastics and how these antimicrobials can be incorporated into the materials will be presented. The lecture will be supported by a review of testing methods and related efficacy.

Speakers include Mai Ha, Senior Product Development Engineer, Microban.

Impact of novel materials on medical device design, and vice versa

A variety of specialty materials that are utilized to compose today’s sophisticated medical devices are chosen based on particular needs and functions that they can support. In recent years, many of the industry’s novel materials have been brought to market by resin and specialty-material suppliers, including multi-functional composites, high-performance resins and metals, bioresorbables, and bioactive composites (including those with pharmaceuticals).

Shifts in medical-grade materials have been linked to improved durability and reusability, compatibility with additive manufacturing, reduced biocompatibility risk, lower cost manufacturing, and greater sustainability. This session will offer a review of those medical devices with Class II and Class III patient contact while fostering a discussion on how new materials are impacting medical device design. Coverage will also include insights on how new device types are driving adoption of new materials with several case study reviews supporting the evidence presented.

Speakers include Rob Klein, Senior Principal Materials Engineer, AtriCure.

Innovations in tube-to-connector joining for device manufacturing

There were nearly 1,000 medical device recalls in 2023, a reported increase of 7% compared to 2022. As a potential source for recalls, tube-to-connector joints must be strong and hermetic for a device to be viable. Any leakage of fluid will certainly warrant a recall. Conventional methods that have been available to make the tube-to-connector joint include solvent welding and adhesives. These methods require additional chemicals and dry or cure times, however, and there are newer methods that forgo additional chemicals and improve cycle times, such as spin welding and laser welding.

The science of joining techniques, as well as their advantages and drawbacks, will be addressed during this presentation. Discussion will touch on joint strength, testing procedures, and failure modes. Medical device designers will gain new insights on how to develop more robust next-generation devices that are easier to manufacture.

Speakers include Jeff Ellis, Senior Technology Leader, EWI.

The pursuit of sustainability: Plastics, packaging, and patient care

Advancing sustainability is essential for medical plastics and the healthcare industry as a whole to meet environmental goals while maintaining patient safety and care standards. Consumer awareness is pushing the industry to adopt transparency regarding sustainable practices, which have become especially important in aligning healthcare brands with growing demands.

During this presentation, attendees will explore how plastics can contribute to improved sustainability through better material selection, manufacturing, and design while maintaining patient safety and care standards. The session also will explore successful examples of recycling initiatives in the healthcare sector.

Speakers include Tania Ferlin, Director of Sustainability Advocacy, Husky Technologies.

Achieving process excellence in implantable medical device manufacturing

The industrial internet of things (IIoT) is transforming implantable medical device manufacturing by elevating process excellence to new heights. By enabling real-time monitoring, predictive maintenance, and remote management through interconnected devices and sensors, IIoT is improving efficiency, minimizing downtime, and ensuring product consistency.

Moreover, IIoT facilitates continuous product improvement by providing deep insights into production workflows, allowing manufacturers to optimize processes, reduce waste, and enhance product quality. By harnessing IIoT, manufacturers can achieve unprecedented levels of precision, reliability, and safety, ultimately delivering superior implantable medical devices to patients with greater consistency and confidence.

As a parallel benefit, automated data collection and advanced analytics will continue to streamline regulatory compliance while reducing administrative burdens and ensuring adherence to stringent FDA and ISO standards when implemented within IIoT processes.

Speakers include Raghu Vadlamudi, Chief Research & Technology Director, Donatelle (A DuPont Business).

Advances and challenges in microextrusion techniques for medical catheters

The production of catheter liners through advanced microextrusion techniques represents a significant area of innovation when considering the rapidly evolving field of medical device manufacturing. As this industry remains under constant pressure to improve the performance, safety, and cost-effectiveness of products, microextrusion will continue to represent a critical area of advancement with the potential to enhance outcomes and streamline manufacturing processes. However, these advances come with their own set of challenges that must be addressed to ensure successful implementation and market entry. The regulatory landscape is particularly complex, especially when considering the European Union.

This technical talk will provide a comprehensive overview of current catheter liner production, focusing on breakthrough technologies, expected future trends, and a comprehensive understanding of what is required to bring innovative catheter products to market successfully. Attendees will gain valuable knowledge on the latest advances in microextrusion techniques, practical solutions to technical challenges, and strategies for regulatory compliance. Successful case studies that demonstrate practical implementation of various innovations, with an emphasis on the use of polytetrafluoroethylene (PTFE) for microextruded medical catheters, will be highlighted.

A detailed examination of the technical difficulties in microextrusion, especially in producing multi-lumen structures, also will be addressed. Focal points will include the challenges of maintaining dimensional accuracy, ensuring uniform wall thickness, and achieving high-quality surface finishes.

Speakers include Gregory Teh, Global Application Scientist, Medtech Coating Technologies Pte Ltd.

Design for micro-injection molding of medical devices

The market for injection molded plastic is being revolutionized by technological advances, including micro-injection molding. Increasingly utilized for smaller and more complex medical devices that are driven by the need for less-invasive procedures, bioabsorbable implants, portable diagnostic tools, and more, micro-injection molding enables the large-scale manufacture of precision components with intricate geometries. While these components are essential to the functionality of advanced medical devices, the design of micro plastic parts often relies on tooling and processing experience rather than simulation. This work combines simulation and experiments to better understand polymer flow at the micro-scale. 

The insights gained and practical takeaways derived from this presentation will guide future product design, leading to more reliable and efficient micro-molded medical components.

Speakers include Davide Masato, Associate Professor, UMass Lowell.

Enhancing injection mold cooling efficiency with steady state thermal models and composite core technology

Up to 80% of the injection molding cycle is consumed by cooling in the production of medical devices and drug-delivery systems. As such, efficient thermal management is a crucial component. A robust methodology for designing cooling systems using steady-state response thermal models aimed at significantly reducing cooling times and boosting manufacturing efficiency will be introduced during this presentation.

By precisely quantifying cooling challenges and optimizing key design parameters, this innovative approach is expected to provide a streamlined modeling strategy for rapid and effective analysis. Attendees will gain insights into the underlying assumptions and be exposed to real-world case studies that demonstrate how these techniques can lead to faster cycle times and enhanced productivity in the high-precision molding of medical components, including:

Speakers include David Crispino, Senior Engineer, Atalys.

Other sessions of interest at the SPE/MPD MiniTec conference include:

A full schedule will be available soon on the conference website.

The SPE/MPD MiniTec conference runs alongside the MD&M West trade show and conference, featuring more than 1,700 exhibitors involved in the medtech, plastics, automation, and design and manufacturing sectors and dozens of conference sessions. Both events will be held at the Anaheim Convention Center in Anaheim, CA. The two-day SPE/MPD MiniTec starts a day before MD&M West on Feb. 3; MD&M West runs through Feb. 6.