Inside the Medical Compression Molding Process

Need a team of Medical Compression Molding experts for your next contract manufacturing project?

Offering unmatched versatility when it comes to transforming raw materials into intricate products, contract manufacturing is an essential part of bringing many medical tools to life.

At Janco, we leverage compression molding to manufacture large, often complex parts with unmatched precision, all while prioritizing cost-efficiency, innovation, and safety. Thanks to our six decades of experience, you get high-quality products without breaking the bank.

Medical Grade Foam in Compression Molding

With any manufacturing project, the choice of foam material is critical. Especially with medical manufacturing, it’s important to understand your options and the list of regulations and standards for the industry. For many projects, medical grade foam is required. One of the keys to designating a foam as ‘medical grade’ is biocompatibility.

Biocompatibility ensures that the foam materials used in medical devices or packaging won’t elicit harmful reactions when in contact with the human body or bodily fluids. This is particularly crucial in medical applications, where patient safety is the top priority.

Medical-grade foams are engineered to excel in demanding healthcare environments. They’re designed to withstand sterilization cycles without compromising their structural integrity or performance. This ensures that medical devices and packaging remain safe and effective throughout their lifecycle, providing peace of mind to healthcare professionals and patients alike.

Types of Medical Grade Foam

We use several types of Medical Grade foam for a range of projects, including:

Closed-cell cross-linked polyethylene foam: Made from a polyethylene polymer that has been cross-linked to create a closed-cell structure so that each cell in the foam is sealed and isolated from the others. This creates a more dense and rigid material. The cross-linking process also makes the foam more resistant to chemicals and water, and it can withstand higher temperatures than non-cross-linked foams.

Our closed-cell medical grade foams are non-particulating, meaning they do not shed particles during use, guaranteeing a sterile environment for medical devices and equipment.

Microcellular urethane foam: Microcellular urethane foam is a type of open-celled foam made from a urethane polymer. It is created by blowing gas bubbles into the liquid urethane mixture during the manufacturing process, which creates small cells throughout the material. The resulting foam is lightweight, flexible, and has good cushioning properties.

Open-cell polyurethane foam: Open-cell polyurethane foam is similar to microcellular urethane foam, but it has larger cells and is less dense. It is also made from a urethane polymer, but the cells are not sealed like they are in closed-cell foams. Instead, the cells are open and connected to each other, giving the foam a more spongy texture.

Non-cross-linked foam: Non-cross-linked foam is a type of foam that has not undergone a cross-linking process. This means that the molecules in the foam are not chemically bonded together. The result is a low-density and light-weight product.

Benefits of Our Medical Grade Foams

Our team carefully selects the highest quality foams for every medical compression molding project, to provide a range of benefits, including:

1. Excellent shock absorption: Closed-cell polyethylene foam is known for exceptional cushioning and shock-absorbing properties, which makes it ideal for several medical products – especially packaging.
2. Chemical resistance: Some types of medical foam are resistant to a wide range of chemicals, making them suitable for packaging medical devices that may come into contact with substances during travel.
3. Customization: Every project we take on can be customized, which is why we seek out medical-grade foam that is easy to manipulate into the customized size and shape you need.
4. Sterility and cleanability: For medical packaging, the ability to maintain sterility is essential. We help you select materials that will offer superior cleanability and can withstand thorough sterilization processes.
5. Regulatory compliance: We always ensure that your selected materials comply with relevant medical regulations and standards, such as ISO 13485 and FDA guidelines.

Medical Compression Molding Applications

At Janco, we cater to a wide range of medical applications using our compression molding capabilities, including:

• Medical packaging
• Orthopedic implants
• Surgical instruments
• Specialized medical kits

The Medical Compression Molding Process

1. Material Preparation: The compression molding process begins with meticulous material preparation. Depending on the properties of your final product, a specific foam or foam composite is selected. This material is then cut to the appropriate size and shape to fit within the molding tool that we’ll use.
2. Heating: Next, the material, undergoes heating in an industrial convection oven. This heating process softens the material and makes it pliable for molding. Our team carefully controls the temperature and duration of heating to ensure softening occurs without causing degradation or damage.
3. Loading the Mold: Once the correct temperature is reached, the material is transferred into the compression molding press. Next, hydraulic pressure is applied to tightly close the mold. This pressure is carefully controlled, exerting enough force to push the heated material into contact with all of the mold surfaces. The mold is securely sealed to prevent any leakage or irregularities.
4. Compression: Hydraulic pressure is maintained for a predetermined amount of time, allowing the material to flow and conform to the mold cavity, ensuring the product achieves the desired shape and density.
5. Cooling: Cooling time might vary depending on factors such as material composition, thickness, and temperature. During this period, the mold is left closed.
6. Mold Release: Once the material has cooled, the hydraulic pressure is released and the mold is opened. Any excess material around the edges of the mold is trimmed or removed carefully by our team.
7. Product Extraction: Finally, the finished product is carefully extracted from the mold cavity.
8. Die Cutting: The product will usually undergo a die-cutting process, where precise cutting tools are used to trim any remaining edges and ensure the final product meets the required specifications.
9. Quality Inspection: Before the product is deemed ready for use, All products undergo thorough quality inspection for regulatory requirements before being approved for shipment.

Our thorough medical compression molding process eliminates the need for secondary cutting operations, reducing both time and costs associated with production while ensuring safety and quality.

Need Medical Compression Molding Services?

For sixty years, Janco has been a trusted partner for high-quality medical compression molding services. With our commitment to quality, innovation, precision, and safety, our team is dedicated to delivering value-add solutions to exceed your needs.

For unmatched expertise in Medical Compression Molding Services, get in touch with our team to discuss your next project.