Advancing Precision in Orthopedic Sports Medicine: PDC’s Expertise in PEEK Injection Molding

At PDC, we’re passionate about pushing the boundaries of precision manufacturing to enhance patient outcomes in orthopedic sports medicine. With our specialization in precision injection molding, particularly using PEEK material, we’re proud to support the development of innovative solutions for ligament and tendon attachment. In this post, we’ll explore several applications and products in this field, as well as key considerations for injection molding to ensure their success. 

Applications and Products for Ligament and Tendon Attachment using PEEK Material: 

  • Interference Screws: Interference screws made from PEEK are commonly used in ligament reconstruction surgeries, particularly for ACL (Anterior Cruciate Ligament) repair. Their biocompatibility, radiolucency, and mechanical properties make them an ideal choice for securing grafts in bone tunnels. 
  • Suture Anchors: PEEK suture anchors provide a secure means of attaching sutures to bone during soft tissue repair procedures. Their lightweight yet durable nature allows for reliable fixation while minimizing the risk of implant migration or irritation. 
  • Tendon Interference Devices: PEEK-based devices for tendon attachment offer surgeons a versatile solution for a range of tendon repair procedures, including rotator cuff repairs in the shoulder. These devices provide strong, stable fixation while promoting natural healing processes. 
  • Intraosseous Devices: PEEK intraosseous devices facilitate the fixation of soft tissue to bone, offering a reliable method for stabilizing ligament and tendon grafts. Their radiolucent properties enable clear visualization during postoperative imaging, enhancing surgical precision. 
  • Anchor Pegs for Ligament Augmentation: PEEK anchor pegs are utilized in ligament augmentation procedures to enhance stability and promote healing. Their biocompatibility and mechanical strength make them well-suited for applications requiring long-term implantation. 

Key Considerations for Injection Molding to Support These Applications: 

  1. Material Selection: Choosing the right PEEK material is critical to ensure compatibility with the intended application. Factors such as biocompatibility, sterilization compatibility, and mechanical properties must be carefully evaluated. 
  2. Design Optimization: Collaborating closely with design engineers is essential to optimize part geometry for injection molding. Features such as undercuts, draft angles, and wall thickness must be carefully considered to ensure manufacturability and part performance. 
  3. Tooling and Mold Design: High-precision tooling and mold design are essential for producing complex PEEK components with tight tolerances. Utilizing advanced machining techniques and mold coatings can enhance part quality and longevity. Venting, cooling, and shut off locations are all critical factors for optimal part molding. 
  4. Process Control: Implementing rigorous process control measures, such as Scientific Injection Molding (SIM), ensures consistency and repeatability in part production. Monitoring key process parameters, such as temperature and pressure, is essential to mitigate risks and maintain quality standards. The high processing temperature of PEEK requires precise cycle times and temperature control for successful injection molding. 
  5. Quality Assurance and Regulatory Compliance: Adhering to stringent quality assurance protocols and regulatory requirements is paramount in the medical device industry. Robust testing, validation, and documentation processes are essential to ensure compliance and patient safety. 

At PDC, 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.