Precision Molded Parts Deliver Drug Compatibility, High Purity, and Dimensional Stability
Plastikos Inc., a leading custom injection molder, and its sister mold making company Micro Mold, both based in Erie, Pa., have successfully commercialized disposable cartridge components made of cyclic olefin copolymer (COC) for wearable drug delivery devices for medications such as insulin and pain medicines. Plastikos has commercial projects underway with U.S. drug delivery device manufacturers. Meanwhile, the company is also exploring uses for COC in other related drug delivery applications.
Plastikos is one of 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® cyclic olefin copolymer (COC) from TOPAS Advanced Polymers, are manufactured under strict performance qualifications including highly challenging tolerance levels 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.
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About Plastikos Inc. and Micro Mold
Micro Mold & Plastikos specialize in precision mold design and fabrication as well as tight-tolerance injection molding. Their unique Lifetime Mold Warranty program is a testament of their devotion towards manufacturing the highest quality products for its customers. Primary fields of expertise relating to plastic manufacturing include medication delivery systems, surgical eye care, microfluidic, and electronic connectors, among others. A medical molding room is controlled through an ISO 7 cleanroom (Class 10,000) with press tonnages ranging from 88T - 220T. Both companies have achieved leading industry recognition as the Processor of the Year and Employer of the Year, presented by Plastics News. For more information, visit www.plastikoserie.com.