MANUFACTURING: FROM POLYMER TO FINISHED PRODUCT

Polymerization

Standard and customized medical-grade resins are produced on site to meet unique and exacting customer requirements. Virgin resins and compounded forms (dyes, inorganic filler, blending, etc.) are produced for additional processing via extrusion, injection molding, or solvent processing.

Extrusion

Monofilament
Melt extruded filaments in a variety of diameters, typically from about 0.10mm up to 2mm. Monofilaments can be further oriented to increase tensile strength and modulus, or to enhance flexibility.

Multifilament
Melt extruded multifilaments from 2 to 88 ends and between 1.5 and 30 denier per filament. Multifilament fibers are oriented in-line and supplied on spools or cones for downstream processing.

Microfilament
Melt extruded single filament fibers with small diameters, typically between 30 and 150 µm. Microfilaments can be further oriented to increase tensile strength and modulus and are supplied on a variety of spools or cones for further processing.

Film
Melt extruded films range in width and thickness for a variety of applications. Typical thickness is between 0.05 and 0.5 mm and can be supplied on a roll with or without a backing material.

Tubing
Melt extruded profiles and round tubing are prepared in a variety of sizes and shapes for additional processing. Parts can be annealed to increase crystallinity and part stiffness.

Compounding
Filament materials can be compounded to incorporate inorganic content, such as barium sulfate or tantalum for radiopacity, or to include other bioactive materials.

Fiber Processing

After extrusion, extruded parts can be processed by orientation to enhance crystallinity and strength. Annealing/heat treatment cycles are also used to stabilize the construct and relieve internal stresses that may damage shelf life and degradation performance.

Textiles

Warp Knitting
Raschel warp knitting is available to co-knit up to four different materials in a wide variety of patterns. Both monofilament and multifilament yarns can be used to create customized mesh fabrics.

Weft Knitting
Circular knit constructs in a wide variety of densities with diameters from 0.25 to 6 inches.

Braiding
12- and 16-carrier braiders produce a variety of customized braids. Axial and core insertions are also available.

Surface Treatment

Coating
Continuous coating of suture and fiber materials and batch coating of textile constructs to modulate lubricity or enhance other performance characteristics.

Chemical Modification
Side chain modification of polymer surfaces to add specific chemistries, like succinate or amine groups. This process is performed in a batch operation.

Packaging

Ultra low-moisture content drying and packaging is employed to assure the longest product shelf stability. High-barrier foil laminates and hermetically sealed pouches provide low-moisture and oxygen permeability. Clamshell packaging is often used to provide further protection.

Labeling

Poly-Med, Inc. materials and components are fully traceable, from raw materials to finished goods. Our labeling provides critical lot information and product attributes that are easily readable and printed on thermally printed label stock.

Sterilization

We utilize industry-leading partners for Ethylene Oxide (including low-temperature cycles), Gamma and E-beam sterilization, and can coordinate and maintain product-specific validations for a variety of products.