By BMP Medical
July 14, 2022
BMP Medical; a US-based, global end-to-end custom plastic contract manufacturing partner in the medical device industry, is pleased to announce the promotion of John Faulkner to Vice President of Sales and Marketing. After holding several management positions since joining the team, John will now assume responsibility for all sales and marketing activities for the company.
“John brings a wealth of experience to the BMP Medical management team,” said Michael Faulkner, Chief Executive Officer & President. “We have long relied on John’s expertise in developing new strategic business and management programs, strengthening existing customer relations, and establishing new ones. His appointment reflects BMP Medical’s ambition to further develop our position globally, so we look forward to his contributions as the company continues to grow."
John knows BMP Medical inside and out because of his years with our tightly knit, family-owned business in the medical device industry. His past positions have given him a strong working knowledge of all program management aspects for medical device contract manufacturing within BMP Medical.
“I am excited in my new role with the BMP Medical team,” said John Faulkner, Vice President of Sales and Marketing. “BMP Medical has a successful track record of global growth. I look forward to collaborating with the team, expanding the company’s capabilities, and delivering improved productivity and performance for our customers into the future.”
John attended the University of Lowell, Southern New Hampshire University, and Lasell University, where he focused exclusively on Business Administration and Management. He also holds several licenses and certifications, such as a Managerial Leadership Professional Certificate, Leadership Development Program Certificate, Industrial Design and Plastic Product Design Certificates, Injection Molding Essentials License, and Math for Molders License.
About BMP Medical
BMP Medical provides plastic contract manufacturing services to leading medical device and diagnostic customers in need of injection molding and injection-blow molding. BMP Medical’s 80,000 sq. ft. facility is headquartered in Sterling, Massachusetts. BMP Medical is a global contract manufacturer servicing the Medical Device and Medical Diagnostic markets in all areas, including, but not limited to, IVD, IV access, sample-preparation devices, and lateral-flow technologies. BMP Medical can service our partner requirements on a worldwide basis. Certifications: ISO13485:2016; FDA registration #1220502; ISO Class 8 injection molding; ISO Class 8 assembly & packaging; 21 CFR 820 Quality System Regulation; FDA registered; and MedAccred certified. Services Offered: Class 7 Assembly, Clean Room Manufacturing (Class 8), Clean Room Packaging and Assembly (Class 8), Custom Assembly & Packaging, Custom Injection Blow Molding (IBM), Custom Injection Molding, DNase- and RNase-free manufacturing, FDA Registered Facility, Product design & development services, R&D tooling, and Sterilization services.
In 2021, BMP Medical began the process of implementing an DelmiaWorks manufacturing ERP execution MES/data-collection software. By mid-2022, the implementation is expected to be completed. DelmiaWorks real-time monitoring, project management, and cloud-based key features will allow BMP Medical to better serve leading medical device OEMs. For Real Time Management, Advanced Manufacturing, Financial Management, MFG Manufacturing & Scheduling, CRM & Sales Order Management, Quality & Compliance Management, Distribution & Warehouse Management, and every operation in between, DelmiaWorks will assist in the automation of our facility and shop floor processes. DelmiaWorks is considered the gold standard and has been exclusively focused on the manufacturing industry for almost 25 years.
Employees have been engaged in the training phase of the process in our new, on-site training facility. DelmiaWorks will eliminate manual processes and redundancies, reduce inventory carrying costs, increase operational efficiencies, protect brand integrity, and produce concise and accurate accounting.
“We are excited to expand our commitment to ensuring customers’ success with the launch of the DelmiaWorks program,” said Michael Faulkner, Chief Executive Officer & President of BMP Medical. “We are eager to optimize the DelmiaWorks software so we can maximize growth and profitability for our customers. The insights and efficiencies gained from DelmiaWorks will help us remain a global leader in customer plastic manufacturing.”
“The DelmiaWorks process is helping us to further streamline our program management systems and company-wide processes, and also to strengthen customer relationships and create new customer opportunities,” said John Faulkner, Sales & Program Manager.
About BMP Medical
BMP Medical provides plastic contract manufacturing services to leading medical device and diagnostic customers in need of injection molding and injection-blow molding. BMP Medical’s 80,000 sq. ft. facility is headquartered in Sterling, Massachusetts. BMP Medical is a global contract manufacturer servicing the Medical Device and Medical Diagnostic markets in all areas, including, but not limited to, IVD, IV access, sample-preparation devices, and lateral-flow technologies. BMP Medical can service our partner requirements on a worldwide basis. Certifications: ISO13485:2016; FDA registration #1220502; ISO Class 8 injection molding; ISO Class 8 assembly & packaging; 21 CFR 820 Quality System Regulation; FDA registered; and MedAccred certified. Services Offered: Class 7 Assembly, Clean Room Manufacturing (Class 8), Clean Room Packaging and Assembly (Class 8), Custom Assembly & Packaging, Custom Injection Blow Molding (IBM), Custom Injection Molding, DNase- and RNase-free manufacturing, FDA Registered Facility, Product design & development services, R&D tooling, and Sterilization services.
This plastic injection molding process guide is intended to provide useful information about injection molding considerations, processes, the primary work leading up to getting a mold on a press, and the many caveats that go into producing a finished molded part. We hope you find this guide useful. It is intended for potential customers, engineers, designers, and outsourcing purchasing professionals.
What is plastic injection molding?
Simply stated, the plastic injection molding process injects heated plastic substrates into a metal-tooled cavity of the desired shape and it is allowed to dry, cure, and set.
But not so quick—let’s do a deeper dive into the step-by-step processes and the caveats evolved throughout the entire process to manufacture a finished plastic injection-molded medical device.
The plastic injection molding manufacturing process is ideal for consistently producing finished components or parts in a cost-effective manner. The up-front tooling process can be rather costly, so it is really only suitable for medium- to large-volume manufactured parts. This manufacturing process produces very little material waste, and the leftover thermoplastics can be recycled.
SIM
Scientific injection molding (SIM) is a data-driven, scientific approach. Cycle times are minimized, machine efficiencies are improved, and productivity is increased. Scientific injection molding is a strong tool supporting the objectives and practices of a lean manufacturing culture. SIM reduces or eliminates many of the forms of waste by providing a robust, predictable molding process.
Plastic injection molding guide process:
First, based on your CAD drawings and 3D printed prototype, a decision needs to be made on which injection molding process is best.
Commonly used plastic manufacturing techniques
The most commonly used plastic manufacturing techniques are injection molding, injection blow molding, two-shot molding, insert molding, rotational molding, compression molding, extrusion molding, and thermoforming. The requirements and specifications of your finished product will determine which injection molding process is best for your finished part.
What is plastic injection molding?
Injection molding is ideal for many small precision medical and large automotive part applications. This is the most commonly used plastic manufacturing process, and it offers a great deal of flexibility in material choices that can change the appearance of the final product.
What is plastic injection blow molding?
Injection blow molding is used in manufacturing parts that need to be hollow and maintain a uniform wall thickness. This process utilizes the blowing of air into the thermoplastic cavities until the desired shape is formed. Bottles are a common product manufactured by this method.
What is plastic two-shot molding?
Two-shot molding has a few names, it is also known as 2-shot, dual-shot, and double-shot molding. This process combines two parts into a single molded part by combining two machining processes. It offers flexibility for combining different resins materials together.
What is plastic insert molding?
This is a single-step process where two parts are formed together. This process is best suited for parts that need to form together tightly.
Plastic injection molding guide considerations:
Key considerations for the manufacturing process selection and thermoplastics material choice:
• Overall design
• Functionality
• Shelf life of the product
• Cost
• Tensile strength
• Shock absorbance
• Impact tolerance
• Scratch resistance
• Heat resistance
• Performance
• Stability
• Chemical resistance
• Final product weight
• UV protection
Plastic injection molding guide Thermoplastic Material Selection
Which medical-grade thermoplastic should be used for manufacturing the medical product?
• Polyethylene
• Polypropylene
• Polystyrene
• Polymethyl methacrylate
• Polyvinyl chloride
• Polyamides (nylons)
• Acrylonitrile butadiene styrene (ABS)
• Polycarbonate
Our blog Common Thermoplastics in Injection Molding (https://www.bmpmedical.com/blog/common-thermoplastics-in-injection-molding/) provides an in-depth review of the different thermoplastics used in medical products, their key benefits, and their tensile strength in psi. Given the precision required in most medical devices, it is generally best to avoid resins that have asymmetrical shrinkage.
Injection Molding Tooling
Mold tooling is essential in producing an accurate and cost-effective manufactured product.
These key tool-making considerations need to be made before the injection molding process can begin:
• Cooling compensation
• Tool mold size and material selection
• Designing, building, and debugging the mold
• Gate placement
• Polishing process, mold fitting, and assembly
• Mold fitting and trial prototyping
How the injection molding press works
The Injection molding manufacturing process
Injection molding is a very complex process. The actual machine has three major parts: the injection unit, the mold section, and the clamp. Thermoplastic pellets are fed into the hopper of the unit and then pushed into the barrel. A turning screw pushes the thermoplastic pellets forward. Heater bands surround the injection unit, melting the thermoplastic pellets. The screw continues to turn, pushing the molten into the open cavity area of the mold. It opens and the part is ejected. The mold closes and the process repeats.
Injection molding monitoring is an ongoing process
The machine operator and engineer continuously monitor the following predetermined parameters to deliver a quality product:
• Injection plasticizing pressure
• Mold, nozzle, air, melt, and cooling temperature
• Filling time
• Packaging and holding time
Why BMP Medical should be your next plastics manufacturing partner
Located in the United States, BMP Medical is near Leominster, Massachusetts, where Pioneer Plastic City was founded, and the region has many thriving plastic manufacturing companies.
BMP Medical provides plastic contract manufacturing services to leading medical device and diagnostic OEMs in need of injection molding, injection blow, two-shot, and insert molding. BMP Medical’s 80,000 sq. ft. facility is located in Sterling, Massachusetts. We foster strong trust-driven relationships to develop inventive solutions tailored to customer and end-user needs.
From concept through commercialization, BMP offers in-depth problem-solving backed by deep industry knowledge and operational excellence.
BMP Medical is a global contract manufacturer servicing the Medical Device and Medical Diagnostic markets in all areas, including, but not limited to, IVD, IV access, sample-preparation devices, and lateral-flow technologies. Headquartered in Sterling, Massachusetts, BMP Medical can service our partner requirements on a worldwide basis.
Certifications: ISO13485:2016; FDA registration #1220502; ISO Class 8 injection molding; ISO Class 8 assembly & packaging; 21 CFR 820 Quality System Regulation; FDA registered; MedAccred Certified
Services Offered:
• Class 7 Assembly
• Clean Room Manufacturing (Class 8)
• Clean Room Packaging and Assembly (Class8)
• Custom Two-shot Molding
• Custom Assembly & Packaging
• Custom Injection Blow Molding (IBM)
• Custom Injection Molding
• Custom Insert Molding
• DNase- and RNase-free manufacturing
• FDA Registered Facility
• Pad printing
• Product design & development services
• R&D tooling
• Sterilization services
Have a question for our technical team on the plastic injection molding process?
Get to know BMP Medical today.
Understanding what are the most common thermoplastics used in medical device injection molding is very important. Selecting the correct medical-grade plastic material for a project is a critical decision in manufacturing the perfect part. When working with an injection molding CMO medical device and component partner, it is important to work with injection molders that adhere to stringent manufacturing standards.
It has long been considered that polymers have a significant advantage over metals in the context of medical applications because the isotonic saline solution that makes up the body’s extracellular fluid is extremely hostile to metals, but it is not normally associated with the degradation of many synthetic high-molecular-weight polymers.
Polymers are typically classified into three groups
Thermoplastics
Thermoplastics are linear or branched polymers that can be melted with heat. They can be molded and removed using conventional techniques. Reheated wax can be molded into a different shape.
Thermosets
Thermosets are cross-linked polymers that are normally rigid and intractable. They consist of a three-dimensional molecular network. Thermosets cannot be remelted. They degrade rather than melt upon heating.
Elastomers (rubbers)
Rubbers are materials that exhibit elastomeric properties. They can be stretched to extension and will spring back when the stress is released.
Thermoplastics represent 90% by weight of all plastic used worldwide. Unlike most thermoset plastics, thermoplastics are processable without any serious loss of properties.
Common thermoplastics in injection molding
Common polymers and their medical uses
Polyethylene - - common thermoplastics used in injection molding for medical devices
This is by far the most popular plastic used worldwide. It is also called polythene. Polypropylene is 34% of all plastic used. It can be used for low- and high-density products. Generally speaking, high-density polyethylene (HDPE) is much more crystalline, has a much higher density, and is often used in completely different circumstances than low-density polyethylene (LDPE). Polyethylene is considered thermoplastic, but with modifications, it can behave as a thermoset. It is a cost-effective medical-grade material. Polyethylene absorbs almost no water, and it cannot be imprinted or bonded with adhesives without pretreatment. Like other synthetic plastics, it is not readily biodegradable. But it is an ideal material for sensitive medical equipment, devices, and supplies used every day in hospitals. This ideal medical-grade plastic is corrosion-resistant and retains its overall performance and structural integrity after frequent sterilization cycles.
Its high impact resistance, resistance to chemicals, and low moisture absorption make it a choice for medical-grade devices and components. Polyethylene doesn’t fade or retain dangerous bacteria, and it can withstand harsh cleaning agents. It is often one of the materials used in medical implants because it is a porous synthetic polymer that is biologically inert and does not degrade in the body.
Polyethylene is a very versatile material and is often referred to as the “steel” of plastics because it can so easily be customized for a variety of different uses. It is commonly used for containers, bottles, and many tubing applications, but it is vulnerable to UV radiation and is flammable. It has a tensile strength of 4,000 psi.
Product benefits of polyethylene include
Polyethylene is commonly used for tubing applications, connectors, bottles, and plastic surgery implants.
Polypropylene - - common thermoplastics used in injection molding for medical devices
Polypropylene is a thermoplastic polymer used in a wide variety of applications. It is a white, mechanically rugged material and has a high chemical resistance. Polypropylene is used for protective packaging and medical equipment is tough and durable and can be recycled down from cars and households. It can be melted and reformed into plastic pellets that then are used to make new products. In fact, polypropylene bottles and containers are collected for recycling in most curbside programs across the country. Recycling polypropylene helps keep this superhero out of landfills.
Polypropylene’s characteristics make it ideal for tough, robust products, ranging from protective car bumpers to lifesaving medical tools to cold-weather gear for our soldiers. It has a very high tensile strength of 4,800 psi.
Product benefits of polyamide include
Within these different thermoplastic categories, there are thousands of variations to choose from. Ultimately, every OEM needs to consider the material’s hardness, flexibility, weight, and overall cost. Many factors come into play when selecting a thermoplastics to be used for medical device injection molding.
Polypropylene is commonly used to manufacture disposable syringes, membranes for membrane oxygenators, connectors, finger-joint prostheses, nonabsorbable sutures, reusable plastic containers, pharmacy prescription bottles, and clear bags.
Polystyrene
Polystyrene is one of the most widely used plastics. It is an inexpensive resin per unit weight. It is a rather poor barrier to oxygen and water vapor, and it has a relatively low melting point. Polystyrene is generally a glassy transparent and hard type of polymer. It is produced by the radical polymerization of styrene and can be solid or foamed. Polystyrene Petri dishes and other laboratory containers such as test tubes and microplates play an important role in biomedical research and science. For these uses, articles are almost always made by injection molding, and often sterilized after molding, either by irradiation or by treatment with ethylene oxide. It has a very high tensile strength of 3,600 psi.
Polystyrene is used for a range of medical applications, including test tubes, Petri dishes, diagnostic components tissue-culture trays, protective packaging, and disposable plastic cutlery.
Polymethyl methacrylate
Polymethyl methacrylate (PMMA) is a synthetic resin produced from the polymerization of methyl methacrylate. A transparent and rigid plastic, PMMA is often used as a substitute for glass. PMMA is a tough and rigid plastic. In addition, it has almost perfect transmission of visible light. And because it retains these properties over years of exposure to UV radiation and weather, it is an ideal substitute for glass. Because PMMA displays the unusual property of keeping a beam of light reflected within its surfaces, it is frequently made into optical fibers for telecommunication and endoscopy.
It is commonly used to make bone cement, artificial teeth, implanted teeth, denture materials, dental fillings, intraocular lens, and membrane for dialysis or ultrafiltration.
Polyvinyl chloride - - common thermoplastics used in injection molding for medical devices
Polyvinyl chloride (PVC) is one of the most commonly used thermoplastic polymers in the world. It is used most commonly in the construction industry, but is also used for signs, healthcare applications, and as a fiber for clothing. PVC is produced in two general forms: (1) rigid or unplasticized polymer (RPVC) and (2) flexible plastic. Flexible PVC is commonly used in construction as insulation on electrical wires or in flooring for homes, hospitals, schools, and other areas where a sterile environment is a priority, and in some cases as a replacement for rubber. Rigid PVC is also used in construction as pipes for plumbing and for siding.
Some of the most significant properties of polyvinyl chloride (PVC):
Density: PVC is very dense compared to most plastics (specific gravity around 1.4)
Economics: PVC is readily available and cheap.
Hardness: Rigid PVC is very hard.
Strength: Rigid PVC has extremely good tensile strength.
PVC is commonly used to manufacture disposable medical articles, hemodialysis or hemoperfusion, blood tubing line, cardiac catheters, blood bags, and artificial limb materials.
Polyamides (nylons) - common thermoplastics used in injection molding for medical devices
Polyamide, also known as nylon, is a synthetic thermoplastic polymer. It offers an extremely broad range of available properties and is used in cars, combs, pump parts, screws, and in films for food-packaging needs. It is often used as a substitute for low-strength metals, and because of its strength, inflexible nature, temperature resilience, and chemical compatibility.
Polyamide plastic is good for CNC machining, injection molding, and 3D printing. It has a higher impact-strength factor compared to polystyrene, or polycarbonate. And its strength factor can be increased even more by a process called “conditioning” and/or be combined with other materials to improve its overall strength. It is a good option for parts that see a lot of wear and tear.
The range of polyamides available offers many advantages. Nylons tend to provide good resistance to most chemicals. However, it is one of the trickiest materials to mold and requires a strong processing plan in place to prevent variations, defects, and excessive waste. Polyamide in most cases is considerably more costly. It has a very high tensile strength of 76 MPa (11,000 psi).
Product benefits of polyamide include
Nylon (polyamide) fibers are used in textiles, fishing lines, and carpets. Nylon films are used for food packaging, gears and bearings (because of its self-lubricating properties), nylon-bristled toothbrushes, electrical insulations, and cable ties.
Acrylonitrile butadiene styrene (ABS)?
Acrylonitrile butadiene styrene (ABS) is a very common thermoplastic polymer and is ideal for very vigorous critical applications. It is commonly used in part production and 3D-print manufacturing for OEM manufacturers. Essentially, the threehttps://www.merriam-webster.com/dictionary/constituents materials provide a balance of properties: butadiene units impart good impact strength; acrylonitrile units afford heat resistance; and styrene units give the co-polymer its rigidity. ABS is regarded as a good engineering plastic (that is, a substitute for metals in structural parts). It can be injection molded, blow molded, or extruded. And it is also gamma & EtO sterilizable.
The chemical makeup of ABS makes it easy to melt down and reshape repeatedly without degrading its chemical structure. It is a recyclable plastic, and it is one of the easiest plastics to handle because it cools down and hardens quickly.
It is ideal for manipulating with additional machining, painting, gluing, sanding, and so forth. ABS is not very chemical-resistant and shouldn’t be considered for applications that require UV resistances or electrical insulation. ABS has a tensile strength of 5,500 psi. Common thermoplastics in injection molding for medical device
Product benefits of ABS include
Common uses of ABS are nonabsorbable sutures, tendon prostheses, drug-delivery systems, tracheal tubes, safety helmets, cleaning applications, and housings.
Polycarbonate - common thermoplastics used in injection molding for medical devices
Polycarbonate is a group of thermoplastic polymers that contain carbonate groups within the overall chemical structure. It is naturally transparent to visible light and offers good UV protection. It is often used for eyewear lenses and is considered to be a good alternative to glass. Polycarbonate is a very strong material and is relatively shatterproof and is also a common material used in medical devices.
Many polycarbonate grades are used in medical applications. Medical grades can be sterilized using steam at 120° C, gamma radiation, or by the ethylene oxide (Eto) method.
Polycarbonate is four times stronger than fiberglass and gets its strength from its flexibility, so it gives a little upon impact. It ranges anywhere between 35% and 300% more expensive than acrylic. Its strength is measured in MPa instead of psi. It has a very high tensile strength of 70 MPa (10,152.6 psi).
Product benefits of polycarbonate include
Common uses of polycarbonate are protecting the eye from UV light, lighting lenses, sunglass/eyeglass lenses, swimming goggles, and scuba masks.
Do you have a question for our team about common thermoplastics used in injection molding for medical devices? Contact us today.
BMP Medical is your one-stop for custom plastic injection
and injection blow molding for medical devices.
For more than 40 years, we have partnered with leading medical device OEMs to create custom plastic injection molding solutions in both finished medical devices and components. During our discovery process, we review and discuss certain criteria that will lead to the success of your finished injection molded part or packaged finished medical device.
Our BMP team and OEMs collaborate to develop a mutual understanding of several factors that drive the material selection and the actual injection molding process for each manufactured medical device and/or component.
Some of those factors:
BMP works with you closely, from prototypes through full-scale production. Working with an experienced full-time injection molding manufacturing partner will give you greater control over the design, from manufacturing through process development. You can also count on high-quality parts for finished medical devices for optimal performance—and you benefit from a lower total manufacturing cost. Getting BMP involved in the development cycle early is crucial in establishing the needed design requirements to help reduce lead time and overall costs.
Our BMP plastic injection molding capabilities include injection molding, injection blow, 2-shot (two-shot molding), and insert molding (overmolding).
Do you have a question for our plastic injection molding team? Contact us today.
BMP Medical is the first injection molding company to achieve accreditation from MedAccred, a robust program managed by the MedTech industry that provides supply chain oversight via standardized audit criteria. (more…)
While at the Medical Design & Manufacturing (MD&M) and PLASTEC West event in Anaheim, CA, earlier this month, the team at BMP sat down with PlasticsToday to discuss the exciting year ahead. From increased capabilities to the company's role in the future of the medical device industry, here are some of the highlights. (more…)
A medical OEM is an acronym for an Original Equipment Manufacturer that produces medical devices. Medical OEMs are an important part of the medical device manufacturing industry. Because medical devices come in a wide range of instruments, apparatuses, implements, objects, implants, machines, even software or types of material, the medical device manufacturing industry is a vital sector of the economy. One that provides services and products utilized by and in support of global healthcare systems. The medical OEM functions similarly as other OEMs, but there are a number of FAQs that define its unique role in the medical device industry. Specifically: (more…)
BMP Medical, a division of Biomedical Polymers, has announced the opening of their new medical plastics manufacturing facility located in Sterling, Mass. BMP Medical is a plastic contract manufacturing partner to leading medical device and diagnostic OEMs. The new 80,000 sq. ft., state-of-the-art facility will be a premier destination for injection molding, injection blow molding, two-shot, insert molding, and other packaging and assembly manufacturing services. (more…)
As with any industry, medical device manufacturers are governed by industry standards and government regulations. Chief among these standards is ISO 9001—the international standard for quality management systems for companies, businesses, and organizations. ISO first published the standard in 1987. Updated versions were published in 1994, 2000, 2008, with the newest version being ISO 9001:2015. The ISO 9001 quality management standard applies to a wide range of industries, suppliers, and services. A short list includes pharmaceuticals, oil and gas, mining, energy, electronics, steel, banking, health care, hospitality, utilities, biotechnology, and the manufacturing of medical devices. (more…)
