Your Precision Micro Molding Partner.
PDC is a trusted contract manufacturing partner specializing in precision injection molding of complex, tight-tolerance micro molded components for the medical device, life sciences, and biotech industries. With decades of experience in high-performance polymer processing, we support OEMs and product development teams from early-stage design through scalable production.
Whether you are developing miniaturized components for robotic-assisted surgery or high-cavity micro parts for diagnostics, our expertise in designing and manufacturing custom tooling, precision injection molding, and assembly delivers proven reliability.
Advanced Insert Molding Capabilities
PDC's insert molding capabilities precisely encapsulate metal, plastic, or electronic components within tight-tolerance molded parts, streamlining assembly and enhancing structural performance. This process combines dissimilar thermoplastic materials in compact, multi-functional designs while maintaining dimensional integrity, enhancing mechanical performance, and long-term reliability.
Medical Components That Commonly Use Insert Molding:
Plastic to Plastic
- Multi-part diagnostic cartridge housings with molded-in alignment features
- Sensor housings combining rigid and flexible polymer segments
- Wearable enclosures with molded-in transparent windows or seals
Plastic to Tubing
- Catheter hubs and Y-connectors with over molded tubing interfaces
- IV administration sets with bonded fluid paths
- Drug delivery manifolds with integrated thermoplastic tubing ports
Plastic to Rod
- Guidewire handles or introducer devices with molded-in polymer rods
- Surgical instrument assemblies with rod-based actuation components
- Endoscopic tool grips over molded onto polymer core shafts
Plastic to Metal
- Surgical handpiece housings with internal metal reinforcements
- Electrosurgical and robotic instrument interfaces with molded-in metal terminals
- Implantable or wearable components with over molded metal contacts or fixation anchors
Our custom tooling capabilities ensure micron-level alignment between insert and polymer, supporting high-yield, production-scale insert molding for complex medical applications.
Over molding for Multi-Material Precision Components
PDC's over molding capabilities allow for integrated micro assemblies that combine rigid substrates with elastomeric or high-performance secondary materials. This capability supports improved functionality, enhanced user interface, and reduced part count in complex device architectures.
Key benefits of over molding include:
- Tactile and Ergonomic Enhancements – Over molding soft-touch thermoplastics onto rigid frames improves grip, handling, and usability.
- Integrated Sealing Structures – Formation of molded-in-place gaskets or seals.
- Material-Specific Functionality – Bonding of polymers with distinct mechanical, chemical, or thermal properties.
Over molding is especially advantageous in micro molding handheld surgical instruments, robotic tool housings, and sealed wearable device enclosures, where material selection, precision interface geometry, and process control are critical to downstream functionality and regulatory compliance.
- Capillary Components
- Connector Interfaces
- Diagnostic Cartridges
- Dispensing Nozzles
- Housing and Enclosures
- Lateral Flow Assay Components
- Lateral Flow Cell Assay Components
- Microfluidic Chips for qPCR
- Nano Dispensing Tips
- Needle Holders and Hubs
- Optical Components
- Reagent Reservoirs
- Sample Collection and Processing units
- Seals and Gaskets
- Sensor Housings with Low Autofluorescence
- Tamper Evident Caps
- Valve Components
- Cannula Assemblies
- Connector Interfaces
- Containers and Syringes
- Dispensing Nozzles
- Dosage Control Mechanisms
- Drive Unit Assemblies
- Fluid Path Assemblies
- Housing and Enclosures
- Luer Locks
- Needle-Free Injectors
- Needle Hubs and Covers
- Plunger Tips
- Reservoir Components
- Safety Mechanisms
- Seals and Gaskets
- Spring Retainers
- Tamper Evident Caps
- Valve Components
- Arthroscopic Instrument Components
- Bioresorbable Anchors
- Bone Graft Delivery Devices
- Compression Staples
- Connector Interfaces
- Graft Fixation Systems (GFS)
- Housing and Enclosures
- Implantable Fixation Devices
- Interference Screws
- Joint Repair Devices
- Seals and Gaskets
- Surgical Screws
- Suture Anchors
- Tendon Repair Anchors
- Valve Components
- Capillary Components
- Connector Interfaces
- Diagnostic Cartridges
- Dispensing Nozzles
- Housing and Enclosures
- Lateral Flow Assay Components
- Lateral Flow Cell Assay Components
- Microfluidic Chips for qPCR
- Nano Dispensing Tips
- Needle Holders and Hubs
- Optical Components
- Reagent Reservoirs
- Sample Collection and Processing Units
- Seals and Gaskets
- Sensor Housings with Low Autofluorescence
- Tamper Evident Caps
- Valve Components
- Instrument Tips and End Effectors
- Micro Jaws or Grippers
- Forceps Tips
- Micro Gears and Gear Housings
- Torque-limiting Components for Articulation
- Sensor Housings
- Encapsulated Pressure or Force Sensors
- Microfluidic Sensor Housings
- Light Guide Holders for Embedded Optical Sensors
- Overmolded Strain Reliefs for Robotic Arms
- Shaft and Joint Interface Components
- Overmolded Pivot Points or Motion Dampers
- Optical & Imaging Support Components
- Lenses and Lens Holders
- Disposable Tool Inserts
- Anchoring and Fixation Devices
- Balloon Catheters
- Connector Interfaces
- Drug Delivery Ports
- Embolic Protection Devices
- Guidewire Components
- Housing and Enclosures
- Interventional Catheter Tips and Hubs
- Microfluidic Devices
- Radiopaque Markers
- Seals and Gaskets
- Sheath Introducers
- Stent Delivery Systems
- Valve Components
- Vascular Access Ports
PDC is recognized for creating high feature resolution during the prototype phase in a time-friendly and budget-conscious manner. This allows our clients to test a component that matches their model in the desired resin. Our team works closely with our customers to refine and scale their designs, employing rapid prototyping and iterative development cycles to accelerate timelines and achieve high-quality outcomes for even the most complex injection molded medical devices.
Get in Touch
PDC is a market leader in precision injection molding and value-added assembly, partnering with OEMs and Contract Manufacturers worldwide to deliver innovative micro-molded solutions to various medical device, diagnostics, and biotechnology markets. Share your specifications using the form below, and our team will be in touch to discuss your project.
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.
Leveraging deep expertise in COP/COC thermoplastics and advanced micro molding, PDC's core insert molding capabilities enable the reliable production of next-generation NGS flowcells. This plastic solution offers a high-precision alternative to traditional glass lithography, opening new avenues for volume and cost efficiency in genomic sequencing.
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.
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.
As a leader in precision injection molding for proteomics and genomics, PDC is committed to advancing Digital PCR () and Droplet Digital PCR (). We understand that scientific discovery hinges on engineering precision. Our focus is delivering the high-tolerance components required to push the performance boundaries of technology.
As robotic assisted surgery (RAS) systems evolve to deliver enhanced precision, dexterity, and control, the demand for miniaturized, high-performance polymer components continues to grow. PDC is a trusted manufacturing partner specializing in precision micro injection molding, insert molding, and over-molding for the next generation of robotic surgical platforms.
PDC delivers next-generation vascular surgery devices through expert precision molding. By mastering the integration of radiopaque polymers and inserts, we equip medical professionals with cutting-edge tools. Our commitment to stringent quality standards directly translates to improved procedural visibility, better patient outcomes, and higher device reliability.
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.
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.
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.
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.
As robotic assisted surgery (RAS) systems evolve to deliver enhanced precision, dexterity, and control, the demand for miniaturized, high-performance polymer components continues to grow. PDC is a trusted manufacturing partner specializing in precision micro injection molding, insert molding, and over-molding for the next generation of robotic surgical platforms.
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.
Upload your specifications and product models in the form below to start collaborating with an experienced micro molding engineering team.