Design and Development

Your Design & Development Partner.

After over thirty years as an experienced precision micro molding partner, we have compiled extensive knowledge of frequently selected thermoplastic materials. At PDC, our expert micro molding team collaborates with you to optimize design and material choices, ensuring innovative, reliable medical devices that meet the highest standards.

PDC’s knowledgeable technical and manufacturing micro molding teams can advise on key design for manufacturability considerations and material properties across a range of applications while collaborating closely with you to ensure optimal material performance meets your product’s performance requirements.

Based on sound engineering principles, our design for the manufacturing process combines theoretical physics with practical experience to evaluate the potential result of a specific part design or feature, with key assumptions related to material selection, injection molding tooling, and process.

Design for Manufacturability

Design for Manufacturing (DFM) is crucial in micro injection molding as it ensures that the part, tooling, and process design consider the manufacturing constraints and requirements specific to this process.

  1. Part Design
  2. Material Selection
  3. Tooling Design 
  4. Process Optimization 
  5. Measurement & Inspection

Thermoplastic Polymers List

Below is a list of thermoplastic polymers our technical engineering and manufacturing team is highly knowledgeable about, along with their key benefits to aid in selecting your precision micro molding medical devices.

Thermoplastics Summary Pyramid

Polyether ether ketone

PEEK

  • Implantable
  • Biocompatible
  • Good strength and stiffness
  • Chemically resistant

PolyEther-Block-Amide

PEBA

  • Implantable
  • High tensile strength
  • Flexural resistance
  • Capable of over-molding

Polysulfone

PSU

  • Rigidity
  • Optical clarity
  • Stability at high temperatures
  • Excellent processability

Cyclic Olefin Polymer

COP

  • Superior moldability
  • Optimal clarity & low birefringence
  • Surface treatment ready
  • Replicate molding features
  • Rigidity

Cyclic Olefin Copolymer

COC

  • Good flow characteristics
  • Excellent moisture, heat, and chemical resistance
  • Optical clarity and low birefringence
  • Excellent gas barrier properties

Polycarbonate

PC

  • Ease of moldability
  • High heat resistance
  • High tensile, shear, and flexural strength
  • Low coefficient of thermal expansion
  • Dimensionally stable

Poly Methyl Methacrylate

PMMA

  • Transparent
  • High gloss & hardness (when modified)
  • Good rigidity
  • Dimensionally stable
  • Good abrasion resistance

Polystyrene

PS

  • Good dimensional stability
  • Good dielectric strength
  • Ease of moldability
  • Relatively low heat resistance

Acrylonitrile Butadiene Styrene

ABS

  • Mechanical durability
  • Cost effective
  • Ease of moldability
  • Electrical insulation

ABS / PC alloys

  • High impact resistance
  • Dimensionally stable
  • Ease of moldability
  • Excellent performance across hot-cold temperature ranges
  • Electrical Insulation

Polyethylene Terephthalate

PET

(includes elastomeric grades)

  • Shatterproof
  • Flexible
  • Recyclable

Nylon

Polyamide

(includes elastomeric grades)

  • High wear resistance
  • High thermal stability
  • Very good strength and hardness
  • High mechanical damping characteristics
  • Good sliding properties
  • Good chemical resistance

Liquid Crystal Polymer

LCP

  • Excellent chemical resistance
  • Excellent mechanical strength
  • Excellent dimensional stability
  • High dielectric strength
  • Low coefficient thermal expansion

Polypropylene

PP

  • Chemical resistance
  • Heat resistance
  • Moldability
  • Moisture resistance

Polybutylene Terephthalate

PBT

  • Excellent heat resistance
  • Very tough, including at lower temperatures
  • Retains its color very well
  • Good resistance to cracking
  • Good insulating capabilities

Polyethylene

PE

  • Resistant to solvents
  • Durable
  • Electrical insulation
  • Widely available

Styrene Acrylonitrile

SAN

  • Transparent
  • Chemically resistant
  • Ease of Processing

Thermoplastic Elastomers

TPE

  • Cost effective
  • Eco-friendly
  • Easy to process
  • Flame retardant
  • Chemically resistant

Polyetherimide, Ultem

PEI

  • High mechanical strength
  • High rigidity
  • High creep resistance over a wide temperature range
  • High dimensional stability
  • Suitable for steam sterilization

Customer Proprietary Materials

Other

Additives and Fillers

  • Barium sulfate
  • Carbon fiber
  • Color concentrates
  • Glass fibers
  • Nucleating Agents
  • PTFE

As an established precision micro molding contract manufacturer, we have key relationships with suppliers and compounders along with an inventory of many materials that will enable rapid prototyping for development-stage programs. To begin collaborating with our precision molding technical experts, complete the form below and upload your product specifications or models.

Micro Molding Solutions For Your Industry

Within the medical sector, micro molding has applications across both the medical device and life sciences markets. Learn more about the industries PDC proudly serves.

Microfluidic chip

PDC's experience with COP/COC thermoplastics while micro molding, combined with core insert molding competency, supports flowcell technology used in next-generation sequencing, which was previously only served by glass lithography.

woman operating smartwatch

In drug delivery, precision is paramount to ensuring patients receive the proper medication in the correct dosage at the right time. Micro injection molded components have emerged as essential tools in achieving this level of accuracy and control. Explore various applications in drug delivery where these tiny yet powerful components are making a substantial impact.

Xray illustration of leg bones

We’re committed to leveraging our expertise in precision injection molding and PEEK material to drive innovation in orthopedic sports medicine. By partnering with leading medical device companies and orthopedic surgeons, we strive to deliver advanced solutions that improve patient outcomes and quality of life.

Microfluidic chip

As a leading precision injection molding company dedicated to driving innovation in the proteomics and genomics sector, we are pleased to share our expertise and commitment to supporting advancements in Digital PCR (dPCR) and Droplet Digital PCR (ddPCR). At PDC, we recognize the critical role that precision engineering plays in pushing the boundaries of scientific discovery, and we are excited to be at the forefront of this transformative journey.

AI xray of bladder cancer in a woman

PDC specializes in precision injection molding solutions that cater to the unique needs of the urology and women’s health market segments. Our commitment to innovation and quality drives us to support advanced biopsy applications with unparalleled precision and reliability. Explore the applications/products for advanced biopsy and key considerations for injection molding to support these critical medical devices.

Vascular surgery graphic

At PDC, we’re committed to driving advancements in precision injection molding to meet the evolving needs of the vascular surgery market. We're empowering medical professionals with cutting-edge devices that improve patient care and outcomes by harnessing the power of radiopaque inserts and polymers and adhering to stringent quality standards.

Microfluidic chip

PDC's experience with COP/COC thermoplastics while micro molding, combined with core insert molding competency, supports flowcell technology used in next-generation sequencing, which was previously only served by glass lithography.

woman operating smartwatch

In drug delivery, precision is paramount to ensuring patients receive the proper medication in the correct dosage at the right time. Micro injection molded components have emerged as essential tools in achieving this level of accuracy and control. In this post, we’ll explore various applications in drug delivery where these tiny yet powerful components are making a substantial impact.

Xray illustration of leg bones

We’re committed to leveraging our expertise in precision injection molding and PEEK material to drive innovation in orthopedic sports medicine. By partnering with leading medical device companies and orthopedic surgeons, we strive to deliver advanced solutions that improve patient outcomes and quality of life.

Microfluidic chip

As a leading precision injection molding company dedicated to driving innovation in the proteomics and genomics sector, we are pleased to share our expertise and commitment to supporting advancements in Digital PCR (dPCR) and Droplet Digital PCR (ddPCR). At PDC, we recognize the critical role that precision engineering plays in pushing the boundaries of scientific discovery, and we are excited to be at the forefront of this transformative journey.

AI xray of bladder cancer in a woman

PDC specializes in precision injection molding solutions that cater to the unique needs of the urology and women’s health market segments. Our commitment to innovation and quality drives us to support advanced biopsy applications with unparalleled precision and reliability. In this post, we’ll explore three to five applications/products for advanced biopsy and delve into the key considerations for injection molding to support these critical medical devices.

Vascular surgery graphic

At PDC, we’re committed to driving advancements in precision injection molding to meet the evolving needs of the vascular surgery market. We're empowering medical professionals with cutting-edge devices that improve patient care and outcomes by harnessing the power of radiopaque inserts and polymers and adhering to stringent quality standards.