Plastics have long played a key role in enabling the design and production of numerous medical devices. But intensive work continues in design studios and materials labs around the world to advance the technology used to save and extend lives. Here is a sampling of some of that work.
Introducing the world's first bio-pipette
Elm-plastic GmbH, a German manufacturer of dosing aids and primary pharmaceutical packaging, has launched the first commercially available pipette made from bioplastic. The Dudeldorf-based company said it worked with materials maker Biovox GmbH and the German subsidiary of international plastics distributor Ultrapolymers Group.
Bio-Pipette, uses Biovox's MedEco bioplastic, polymers that consist either entirely of polylactic acid or 95 percent bio-based polyethylene. Image courtesy of Elm-plastic GmbH
The product, dubbed Bio-Pipette, uses Biovox's MedEco bioplastic. These polymers consist either entirely of polylactic acid (PLA) or 95 percent bio-based polyethylene (PE). They are approved for use in the medical sector, and the resins are compliant with ISO 10993.
Compared to existing pipettes made of polyethylene or polypropylene, Elm-plastic says this advancement aids sustainability by enabling a 113 percent reduction in the product's CO₂ footprint (cradle to gate). MedEco PLA also can be processed at low temperatures, which translates into significant energy savings compared to molding fossil-based plastics.
Biovox says its PLA is particularly well-suited to producing dimensionally stable injection-molded parts with a non-slip surface. It offers high rigidity and strength, which lends itself to applications with low wall thicknesses.
Elm-plastic is responsible for the product-specific design, manufacturing, and regulatory compliance. Biovox developed and manufactures the medical compounds, and Ultrapolymers Deutschland provided initial consulting services for material selection and processing up to the start of series production.
A PEEK into the future
Brussels-based Syensqo says its medical-grade KetaSpire PEEK resin has enabled the development of a new generation of orthopedic surgical guides made from the advanced polymer. Born out of a 2023 spin-off from Solvay Group, Syensqo collaborated on the project with two leading Brazilian health technology companies — Hanisch Medical and TechImport.
The company says these new guides provide surgeons with a lighter and more radiotransparent alternative to traditional metal instruments. "For decades, the rigidity and weight of metal have limited the evolution of surgical guides," the company said. "The new guides, developed in Brazil, are up to 70 percent lighter than traditional metal versions while maintaining equivalent strength and durability. But the true revolution lies in the radiotransparency of KetaSpire PEEK. Unlike metal, this advanced polymer does not interfere with intraoperative imaging such as X-rays."
This feature allows for greater precision, since surgeons benefit from a clear, unobstructed view. This, claims Syensqo, also can reduce procedure times and increase surgical confidence. Additionally, the ultralight design minimizes surgeon fatigue.
The new PEEK-based guides also are fully compatible with all major sterilization methods, including steam, ethylene oxide, and gamma radiation.
Developing a higher-volume biologics injector
The biologics market is shifting toward higher-volume medication delivery systems to reduce injection frequency and enable home treatment. Suzhou Savicred Biotechnology Co. Ltd. wanted to develop a 2.25ml biologics injector that could reliably handle larger volumes and more viscous formulations while ensuring patient safety and ease of use. This required biocompatible materials that could meet stringent performance requirements without compromising manufacturability.
That's when Savicred, a Chinese medical device maker specializing in drug-delivery and injection systems, chose to work with German materials giant Covestro.
Covestro notes that developing auto-injector solutions for high-volume biologics delivery presents complex design and material challenges. This meant addressing multiple critical requirements simultaneously: maintaining strength in load-bearing components under injection forces, achieving structural integrity in ultra-thin walls (≤1.0mm) to enable compact design, providing clear visibility of the drug solution, and meeting strict biocompatibility requirements for patient safety, all while supporting efficient manufacturing of complex components.
The parties opted to use Covestro's Makrolon 2458 polycarbonate. The high-performance, biocompatible material enabled a strong yet compact design with ultra-thin walls while offering exceptional clarity, dimensional stability, and excellent processability.
Exhibiting a maestro's touch
In a separate development, Covestro tapped into its long-time partnership with Finland's TactoTek Oy. It worked with several partners and used TactoTek's patented In-Mold Structural Electronics (IMSE) technology to create an innovative demonstrative device it calls Maestro.
The device, which has a smooth, illuminated user interface with integrated touch functionality, is designed to provide simulated, non-invasive glucose measurements and improved molecular diagnostic testing via Covestro's polycarbonate materials. By embedding electronics and structure in a single part, the technology "maximizes resource efficiency, design flexibility, and reliability." This allows for intuitive and illuminated seamless smart surfaces for various human-to-machine interface (HMI) controls. Emily Shaffer, Covestro's Healthcare market manager, said the firm's Makrolon Dx PC resin "provides optical clarity that helps deliver improved molecular diagnostics."
Addressing regulatory concerns
So-called "forever chemicals" are under attack. These materials — per- and polyfluoroalkyl substances (or PFAS) — historically have been used in cookware, packaging, and some medical products because of their non-stick, stain-resistant, and fire-retardant properties. But now many governments are in the process of phasing them out, leaving the plastics industry scrambling to find alternatives.
The following two products have been previously reported but are worth briefly recapping here, given the attention being given to this highly contentious topic.
Sabic goes PFAS-free in a PC copolymer
Saudi Arabia-based chemical giant Sabic recently introduced the first PFAS-free grade in its family of PC copolymer resins. Dubbed LNP Elcres NPCRX9612U, the biocompatible, medical-grade material is well suited for healthcare applications. It has chemical resistance that allows it to withstand harsh healthcare disinfectants, is impact-resistant, and enables the type of thin-wall molding often needed to make such products as insulin pumps and diagnostic monitors.
A PFAS-free additive
Materials design firm Techmer PM, meanwhile, recently partnered with compounder Premix Group to introduce a fluorine-free additive aimed at use in precision labware. The formulation, called TechSurf Low Retention, can be introduced as a masterbatch and dosed with a gravimetric feeder or pre-compounded into a ready-to-use pellet. It's designed to deliver clean fluid release and volumetric accuracy in fluid-management applications such as pipette tips, microplates, and diagnostic devices.
Clinton, TN-based Techmer PM says, "These patent-pending and fluorine-free formulations have been validated with various surfactants, organic solutions, deionized water with food dyes, elevated heat aging studies, migration testing, and molding trials." The company says the additive, which has been pre-tested for use in multiple grades of polypropylene, has been "designed to help evacuate fluids from molded pipette tips."
Tools for real-time health monitoring
Finally, the
Wiley Online Library
reports there is an overarching trend toward patient-specific, multifunctional devices. “As these devices evolve, the integration of biosensors with 3D-printed polymers could allow for real-time health monitoring, further enhancing the personalized care experience. The main bottlenecks.” It says, “remain regulatory approval pathways and optimizing compatibility between specific polymers and printing methods (FDM, SLA, SLS, bioprinting, etc.).”