Resources & Articles

Orthopedic Foam Products and Packaging Materials

For about six decades, our team has manufactured a wide range of products that are essential to the medical industry.

While our proficiencies are wide-ranging and encompass several sectors, including auto, industrial, and electronic, medical manufacturing projects require an extra degree of attention and expertise.

The medical industry itself is diverse and includes many unique fields. Our team has experience manufacturing and packaging products for orthopedic surgeons, including knee and hip products that are manufactured in our ISO-certified class 8 cleanrooms.

To help you understand our process and your options, this resource covers:

  1. Orthopedic Products
  2. Our Manufacturing Process
  3. Material for Orthopedic Products
  4. Industry Standards and Regulations
  5. How Janco Can Help

Orthopedic Products

We work with our customers to customize every project, meaning that we take the time to understand your needs, assess your design specifications, and ensure that your end product is as valuable as possible.

Most commonly, the orthopedic products manufactured by our team include packaging for:

  • Knee and hip products
  • Hip stem implants
  • Knee implants
  • Shoulder implants

Our Process

All products are manufactured in one of our class 8 cleanrooms utilizing the highest quality foam fabrication machinery. Die cutting, compression molding, and thermoforming are the most common manufacturing methods used when creating orthopedic products, depending on the exact application.

Our team of experts works directly with you to assess your design ideas for manufacturability and search for ways to add value and ensure precision and quality.

We’ll help you understand your options, including the color and thickness of your foam selection so that you can make informed decisions that guarantee your products are strategic and sustainable without compromising your vision.

Materials for Orthopedic Products

Most often, closed-cell, cross-linked polyethylene foams are used for orthopedic projects.

Cross-linked polyethylene is a high-density foam that is manufactured when a catalyst is added to the thermoplastic resin, which turns it into a thermoset. The catalyst creates covalent bonds that link the molecules together, resulting in them being closed-cell.

Closed-cell foam is defined as being compact and resistant to water. It’s also known for its flexibility and chemical resistance.

Most commonly, we use Zote or Volara foam when choosing from closed-cell materials for medical manufacturing.

Industry Standards and Regulations

Our decades of experience mean that our team has a deep understanding of the unique industry standards that govern how we manufacture medical products and packaging. Product manufacturing is completed in a class 8 cleanroom, while all packaging is done in a class 7 cleanroom.

In addition, products such as hip stem and knee implants often undergo testing to examine:

  • Phototoxicity – Phototoxicity testing is used to identify and measure the potential of chemical agents to induce toxicity.
  • Bioburden – Bioburden testing measures the microbial contamination levels on or within a product. This type of testing can be conducted from the raw materials used in the manufacturing process or once a product is complete.
  • Particulates – Particulate testing includes procedures designed to count and remove particulate contaminants in various medical devices.

The Foam Center of Excellence

Our newest cleanroom is one of our greatest achievements, designed to improve how we service clients and give us the capabilities to machine larger, more complex parts and products.

Our state-of-the-art machinery ​​offers the largest capabilities in the industry, able to manufacture parts as large as 30” by 60”.

Orthopedic Foam Products and Packaging with Janco

Need a partner you can trust for your next orthopedic manufacturing project? From design through to packaging, Janco will provide the guidance, support, and execution you need, adding value at every stage.

Get in touch to tell us about your project and learn how we can help.

  • This field is for validation purposes and should be left unchanged.