Flexible Material Converting

• Rotary die cutting
• Flat bed die cutting
• Kiss cutting
• Plotter cutting
• Large format die cutting
• Guillotining
• Multi-zone laminating
• Wide web laminating
• Rewind slitting
• Lathe slitting
• Island and multi-island placement
• In-line lot, barcode, and UDI printing for brand identification and batch traceability
• Flexographic printing
• Inkjet product marking in-line printing
• Material perforation and scoring
• Pouching & packing – carton printing and packing, heat seal pouching, foil based pouching, thermoformed pouching, 4 side sealing, platen sealing, vision systems and sterilization
• 3D printing and rapid prototyping
• Corona treatment
• Tube filling
• Full medical device assembly
• RF welding

The adhesive and backing tapes utilized in the production of your medical device are determined primarily by its key function or purpose. For example, a wound care dressing intended for joint coverage necessitates the use of medical adhesive and robust materials capable of withstanding increased movement and perspiration compared to a medical tape used in surgical procedures.

Before making the final selection, various other factors must be taken into account, including the anticipated duration of wear, the potential fragility or sensitivity of the user’s skin, and the level of breathability required. To ensure a comprehensive understanding of your project and the device’s technical specifications, we will engage you in a series of inquiries before presenting our proposed solution.

With our extensive expertise, we proficiently produce a diverse array of products, employing various medical adhesives.

The selection of the appropriate adhesive for your device is of utmost importance. Insufficient adhesion may result in the device not remaining in place for the necessary duration to achieve its therapeutic effects. Conversely, excessive adhesion can lead to mechanical trauma when removing the tape.

• Silicone adhesives
• Acrylic adhesives
• Synthetic rubber adhesives
• Hydrocolloid adhesives
• Custom tapes and adhesives

The chosen material(s) for your medical device must offer flexibility corresponding to the movement of the specific body part it is designed for, while ensuring adequate support for the medical adhesive to prevent undesired peeling. Here are some of the materials we utilize in the production of medical devices:

• Stiff polyester
• Paper
• Non-woven materials
• Woven materials
• Medical films
• Medical foams
• Microfluidic
• Hydrofilic and Hydrophobic films

Benefiting from a profound comprehension of flexible material technology and conversion processes, coupled with our steadfast commitment to confidentiality, we possess a distinctive capacity to completely oversee your project internally.

Our adept team of professionals will provide comprehensive guidance in material selection, product design, packaging formats, and product specifications, ensuring a full CE mark from start to finish. Collaborating closely with your team or individuals, our dedicated product development and project management team will deliver the most cost-effective and innovative solutions to the market.

Equipped with CAD drawing facilities, an extensive array of sample materials, and global reach through video conferencing, we facilitate swift and precise development with clients worldwide. Continual investment in this aspect of our business solidifies PolarSeal’s position as the trusted advisor in the healthcare and flexible material conversion sector.

Our partners rely on PolarSeal for our expertise in materials and conversion, whether the challenge is to enhance an existing product, improve product efficiencies, or discover a solution that facilitates the launch of a pioneering innovation. Our objective is to utilize PolarSeal’s research and development capabilities to create distinct value through the introduction of new and improved products and innovative methods to reduce costs, or both.

Furthermore, PolarSeal will oversee your project from inception to completion, as well as manage ongoing volume manufacturing. This comprehensive process includes the creation of product specifications, obtaining CE marking for your product, conducting all relevant tests, and even handling product branding and packaging design. Within our in-house laboratory, we possess state-of-the-art R&D equipment to ensure a rapid response during the development and refinement of products for the market.

Prototype products are manufactured using full-scale production machinery, ensuring a seamless transition from prototype to full manufacturing runs. Our meticulous processes are rigorously followed for any new product, and we generate a complete Installation Qualification, Operational Qualification, and Performance Qualification in accordance with a fully audited validation master plan.