All in one piece

The increasing demand for plastic or silicone products manufactured using microextrusion or micromoulding processes can, among other reasons, be attributed to the excellent properties of the material. (In the picture: micro-silicone mold parts in front of a U.S. one-cent coin.) (Source: Flexan)

Above all, the biocompatibility of the material enables trouble-free use in the manufacture of medical devices. Furthermore, the chemical and thermal stability of the silicones, as well as their bacterial resistance, support the use of the material in the medical sector. In the picture: extrusion hoses next to a match head. (Source: Flexan)

While the low viscosity of the material provides an advantage in the production of thin-walled products and also allows for complex geometries, the various consistencies of silicones available on the market require extremely precise tooling to prevent leaks and flash formation. (In the image: micro-silicone mold parts compared to a matchstick head.) (Source: Flexan)

Multilumen or multi-lumen catheters are required with increasingly smaller diameters and thinner walls. The multilumen catheter in the picture easily passes through a needle eye. (Source: Flexan)

With the acquisition of IntroMED LLC in April of this year, the Flexan Group has successfully continued to expand and broaden its own portfolio. The contract manufacturer of patented insertion sets for catheter placement significantly contributes to the fact that the globally operating contract manufacturer Flexan has been able to further increase its manufacturing depth in the medical technology sector and expand its value creation depth. In connection with the acquisition of Medron Inc. in 2016, an expert in in-house manufacturing and assembly of catheter end products, and investments in the new headquarters of the FMI medical technology division, the US company strengthened its market position as a full-service provider in the industry. At MEDICA / COMPAMED 2018, the group will now present its entire portfolio; a focus will be on development services and products in the field of micro-injection molding as well as micro-lumen extrusion of medical products based on thermoplastics and silicone.

"In recent years, the demand for medical products made of plastics and silicone, as well as their combination and assembly, has been steadily increasing — along with the quality requirements these products must meet," describes Werner Karau, European Commercial Leader at Flexan. This trend is continuing to grow according to a survey by the American market research company Global View Research. By 2025, the global revenue from silicone medical products is expected to reach approximately 597 million US dollars, with an annual growth rate of an average of 6.6 percent. To focus on their core processes amid these growth rates, OEMs increasingly rely on highly specialized contract manufacturers for the production of individual components. "As a full-service provider in the manufacturing of medical components, Flexan accompanies the entire value chain, from product development through prototype and tool manufacturing to series production with comprehensive quality assurance and logistics," reports Karau.

The rising demand for plastic or silicone products produced via micro-extrusion or micromolding can, among other things, be attributed to the excellent properties of the material. Especially the biocompatibility of the material allows for trouble-free use in the manufacture of medical devices. Furthermore, the chemical and thermal stability of silicones, as well as their bacterial resistance, support the use of the material in the medical sector. However, processing liquid silicone (LSR) is highly demanding. While the low viscosity of the material is an advantage in manufacturing thin-walled products and also allows for complex geometries, the various consistencies of silicones available on the market require extremely precise tooling to avoid leaks and flash formation. "Through long-standing and intensive cooperation with certified tool and mold builders, we can quickly and cost-effectively implement necessary adjustments and modifications during the prototyping phase. This way, we have a custom injection mold available for each order in a short time," says Karau. This flexibility is indispensable, as customer requirements in the extrusion sector generally increase with each new product. Multilumen or multi-chamber hoses are needed with ever smaller diameters and thinner walls. "Our task is to develop the appropriate process and identify the suitable material to realize these products," explains Karau.

At MEDICA / COMPAMED 2018, booth F20-1 in Hall 8b, under the motto "Design – Develop – Deliver," Werner Karau, European Commercial Leader, as well as the US and international teams, will be available to answer all questions regarding the entire portfolio and all services of the Flexan Group.