The Science Behind Making Dissimilar Materials Work Together
What happens when a medical device needs the strength of one material and the flexibility of another? Making those materials work together can open up new design possibilities, but it also introduces some complex manufacturing challenges.
Medical Product Outsourcing recently featured MRPC Director of Technology Development Brunson Parish and Process Engineer Denise Sawdey in a MedTech Makers Q&A focused on multi-material molding and the considerations involved in bringing dissimilar materials together.
Making Different Materials Work Together
Multi-material molding allows medical device manufacturers to combine different material properties within a single component. A rigid thermoplastic, for example, can provide structural integrity while flexible silicone adds patient comfort or creates a seal.
The challenge is getting those materials to work together reliably.
Different materials can have very different processing requirements and may not naturally bond to one another. MRPC can address those challenges through approaches including:
- Self-bonding silicones
- Primers
- Plasma treatment
- Mechanical design features that support adhesion and component performance
These approaches can expand what is possible in a molded component, including combinations of silicone with thermoplastics or metal and features such as internal seals, undercuts, flexible components, and ergonomic grips.
“Adding silicone to metal or thermoplastic allows the design to have geometry and properties that otherwise would be impossible.”
Denise Sawdey, Process Engineer
More Than Just Material Selection
Choosing materials is only part of the equation. The entire application needs to be considered when developing a multi-material component, including:
- Sterilization and environmental exposure
- Implant duration and device requirements
- Regulatory considerations
- Material alternatives
- Performance testing
- Process validation
Understanding these factors early can help manufacturers avoid potential issues later in development and production.
Why Early Collaboration Matters
For MRPC, the opportunity to solve those challenges starts well before production.
Parish highlighted the value of bringing manufacturing expertise into the product development process early, drawing on MRPC’s experience with prototyping, product and mold design, manufacturing equipment, and a broad range of thermoplastic and silicone materials.
“Our experience becomes most useful on the front end of design conception.”
Brunson Parish, Director of Technology Development
That early collaboration can help manufacturers identify potential manufacturing challenges, evaluate bonding approaches, simplify production, and ultimately develop more reliable, high-performance components.
Whether combining silicone with thermoplastics or metal, MRPC’s multi-material molding expertise can help medical device manufacturers turn complex material combinations into manufacturable solutions.
Read the “Making Dissimilar Molded Materials Work Together—A Medtech Makers Q&A” on Medical Product Outsourcing.