High Volume Manufacture Of Thinwall Medical Device Components
With Liquid Crystal Polymer Thermoplastics

(Courtesy : Celanese Chemicals The Chemistry Inside InnovationTM)

Customer value delivered

This collaborate approach to material selection resulted in up to 50% per part cost savings versus the incumbent Polycarbonate material. Savings were realized through greater productivity with shorter cycle times and increased multi-cavity tool (4x versus original). Lastly, the simplified design has allowed for increased flexibility for other components.

Celanese solution & capabilities

Our Broad portfolio of Vectra® MT® LCP includes glass-filled, mineral-filled, higher-flow, tribologically modified (PTFE), and appearance grades – suitable for a variety of uses in medical device applications. There are also countless opportunities for modified grades that provide extraordinary easy flow and low warpage – ideal for highly complex designs and for optimizing material use. This functionality does not come at the cost of Medical compliance, since all Vectra® MT® LCP grades are supported by the Celanese MT® Polymer Service Package including biocompatibility data to support regulatory filings and to reduction of risk through change notification, heightened quality procedures and long-term supply agreements.

When working with the Celanese MT® line of products, our Part Design & Processing team includes industry-leading computeraided engineering LCP design capabilities to allow conceptualization of new part designs before tool production.

Summary

In summary, LCP resins are different but not difficult. Once their polymer characteristics are understood, they can be put to good use in pushing the envelope with advanced designs, part to part tolerance repeatability, and high volume productivity in the tens of millions of units … all with the right design, tooling and processing.

To assist with product development from material selection to production, Celanese has a dedicated technical team specializing in medical applications to work with OEMs, (bio-) pharma companies, molders, design houses, engineering firms and CMOs/CDMOs.

Technical services include a world class tribology lab to help with generating custom test friction and wear data for optimum material pairings in the medical device. This is in addition to our standard CAE support for structural and mold filling analysis and Field Tech Service support for prototype to production mold trials. Selecting the most appropriate medical grade (plastic?) materials for complex electro-mechanical drug delivery devices early in the project can facilitate a successful launch and decrease risk of failure!.