Plastikos shipped nearly eight million COC-based components for drug-delivery devices in 2015

Custom injection molder Plastikos Inc. and sister moldmaking company Micro Mold, both based in Erie, PA, have successfully commercialized disposable cartridge components made of cyclic olefin polymer (COC) for wearable drug-delivery devices. Plastikos has commercial projects underway with U.S. drug-delivery device manufacturers and is exploring uses for COC in related applications.

Plastikos is among the leading medical molders of COC components for drug-delivery devices, with shipments of nearly eight million parts during the past year. The precision disposable cartridges, which consist of several parts molded of Topas COC from Topas Advanced Polymers (Florence, KY), are manufactured under strict performance qualifications including tight tolerances and multi-cavity tooling.

“In these highly demanding applications, we are able to push the limits in terms of precision molding because of the broad material and process know-how we bring to the table,” said Rob Cooney, Manufacturing Manager for Plastikos. The challenging project included the design and construction of multi-cavity molds that range up to 32 cavities with fully interchangeable inserts among all cavities. To further mitigate the risk of shipping a single defective part, every cavity on each mold was designed and built with a cavity pressure sensor. This mold sensor technology is used to monitor every cycle in production and provides 100% traceability.

Plastikos works closely with OEMs and material supplier Topas Advanced Polymers to produce complex geometries and tight tolerances down to less than 0.001 in. (0.025 mm). Topas COC provides purity, drug compatibility, biocompatibility and dimensional stability. The material delivers consistent, reproducible performance and facilitates miniaturization of drug delivery systems. “We have worked closely with Plastikos for several years now, and are very impressed with their ability to scale up incredibly precise designs to meet the needs of healthcare device makers,” said Timothy Kneale, President of Topas Advanced Polymers Inc.

“TOPAS COC fills a vital role in the disposable cartridge because of its repeatable performance in an industry where precision means everything,” said Dan Snyder, Technical Sales Manager for Plastikos. “It’s a well-respected material because of its drug compatibility and other high-performance attributes.”

Unlike other engineering thermoplastics or glass, Topas COC offers a non-ionic, minimally reactive surface. This non-polar substrate does not promote adsorption, denaturation, aggregation or precipitation. With lower leachables and extractables, glass-clear Topas resin preserves long-term drug purity enabling better quality at high yields.

Plastikos’ global supply capability meets the needs of drug delivery manufacturers who sell these devices throughout the world.

Plastikos recently announced that it would achieve a major milestone later this summer when it completes a 17,000-square-foot addition to its facility in Erie, PA, which includes an ISO Class 7 cleanroom. PlasticsToday spoke with Philip Katen, President and General Manager, about the expansion and the company’s strategic pivot into cleanroom molding for medical device OEMs.