Exploring Material Options for Medical Prototyping with Modo Rapid

Developing parts for the medical device industry is a high-stakes process, and material choice is a crucial decision to make at the outset of the project. At Modo Rapid, we understand the importance of selecting the right material and offer a variety of options, including PEEK, PEI (Ultem), PPSU, polycarbonates, medical-grade liquid silicone rubber (LSR), and 3D-printed titanium and ABS-like WaterShed XC 11122. The specific requirements for the part or device being developed will guide the decision on which material is the best choice.

Medical device testing



Material Choices and Their Applications

PEEK, PEI, and PPSU:

These high-performance plastics are excellent for parts that require high temperature resistance and sterilization. They offer great mechanical properties and are often used in surgical instruments and other high-stress applications.

Polycarbonate:

Known for its good clarity and impact resistance, polycarbonate is ideal for applications requiring transparency and durability, such as enclosures and housings for medical devices.

Medical-grade Liquid Silicone Rubber (LSR):

LSR is perfect for flexible parts that need to withstand movement and stress, such as seals and gaskets. It is biocompatible, making it suitable for skin contact applications.

Titanium:

With its high strength-to-weight ratio and corrosion resistance, titanium is ideal for implants and other high-stress components.

ABS-like WaterShed XC 11122:

This 3D-printed material offers excellent clarity and water resistance, making it suitable for microfluidic devices and other applications where visibility and humidity resistance are important.

Low-Density Polyethylene (LDPE)



Comparing Manufacturing Processes

Choosing the right manufacturing process is just as important as selecting the right material. At Modo Rapid, we offer a range of manufacturing processes, each with its own set of advantages:

Injection Molding:

Ideal for high-volume production, injection molding provides repeatable, reliable, and consistent parts. It is suitable for materials like PEEK, PEI, PPSU, polycarbonate, and LSR. The initial tooling cost can be high, but using low-cost aluminum tooling can mitigate this.

CNC Machining:

This process is perfect for low to medium volume production and is highly versatile, allowing for quick production without the need for expensive tooling. It is suitable for PEEK, PEI, PPSU, polycarbonate, and titanium.

3D Printing:

Best for rapid prototyping and low-volume production, 3D printing allows for quick iteration and design flexibility. It is ideal for complex geometries and is suitable for materials like titanium and ABS-like WaterShed XC 11122.



Material and Process Compatibility

Understanding the compatibility of materials with different manufacturing processes helps in making informed decisions:

Material Injection Molding CNC Machining 3D Printing
PEEK, PEI, PPSU X X
Polycarbonate X X
Liquid Silicone Rubber X
Titanium X X
ABS-like WaterShed XC 11122 X



Advantages and Disadvantages of Material Options

Choosing the right material involves weighing the advantages and disadvantages based on your specific application requirements:

Material Temp Resistance Good Clarity Lightweight Suitable for Skin Contact
PEEK, PEI, PPSU X
Polycarbonate X
Liquid Silicone Rubber X X
Titanium X X
ABS-like WaterShed XC 11122 X



Detailed Material Characteristics

PEEK, PEI, PPSU:

These materials offer excellent temperature and chemical resistance, making them ideal for high-stress and sterilization-required applications.

Polycarbonate:

Offers good clarity and impact resistance, suitable for applications needing visibility and durability.

LSR:

Provides flexibility, biocompatibility, and durability, ideal for parts in contact with skin and requiring repetitive motion.

Titanium:

Lightweight, strong, and corrosion-resistant, perfect for implants and high-stress components.

ABS-like WaterShed XC 11122:

Clear and water-resistant, ideal for microfluidic devices and applications requiring visibility.

Conclusion

At Modo Rapid, our comprehensive understanding of material properties and manufacturing processes ensures that we can guide you to the best solution for your medical device prototyping needs. Whether you need high-temperature resistance, biocompatibility, or clarity, we have the materials and processes to meet your requirements. Contact us today to discuss your project and find out how we can help you bring your innovative medical devices to market faster.

With extensive experience in both prototyping and full-scale production of medical devices, Modo Rapid is well-equipped to support designers with detailed feasibility analyses and expert guidance. We are excited to collaborate with you and provide the manufacturing solutions needed to turn your designs into reality.

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