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Medical Plastic Injection Molding

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Medical injection molding

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Medical injection molding is used to manufacture a range of medical components and devices using medical grade thermoplastic materials that are durable, reliable and meet FDA regulations. The medical plastic injection molding process is cost-efficient, and ideal for high volume production runs and applications requiring consistency and tight tolerances.

Stack Plastics can create any number of specialized plastic injection molded medical parts, either as subassemblies or as components for more complex instruments. We are ISO 13485:2003 certified for medical injection molding for all types of components and assemblies and have the expertise working with a wide range of medical grade plastics and injection molding processes.


Medical Injection Molding with Stack Plastics

Using our medical injection molding processes, Stack Plastics produces delivery devices for stents, implants, sutures, and more. We also offer assembly services for subcomponents of larger, more complicated medical devices. In addition to medical injection molding, we manufacture plastic moldings that house other, non-plastic components or mechanisms.

Our insert molding processes can create housings for medical devices including:

  • Needles
  • Surgical blades
  • Tubes
  • And more

Stack Plastics utilizes state-of-the-art vertical medical plastic injection molding workstations dedicated to this process. We have also forged solid relationships with several trusted vendors who supply us with top quality metal components for medical plastic injection molding projects.


Catheter Molding Capabilities 

Our catheter molding capabilities incorporate insert moldingmicromolding, and overmolding processes, along with special biocompatible resins. We can produce catheter tips, luer fittings, joints, markers, manifolds, and more through precision catheter molding, with ceramic or metal components and assemblies included, as needed.


Medical Molding Using Medical Grade Plastic Resins

Stack Plastics utilizes a variety of unique materials for medical plastic injection molding, making it possible for us to provide the ideal medical plastics for your project's needs. We use various engineering resins for our medical injection molding that offer excellent mechanical properties, high tensile strength to resist breakage, and high temperature load ratings to avoid deformation due to heat exposure during sterilization.


Medical Plastic Molding Materials

The medical grade plastics we use for medical injection molding have high molecular weight and feature chemical and heat resistant properties. Each type of thermoplastic used for medical molding also features different advantages and qualities you will want to review before selecting a material for your injection molding application.


  • Polycarbonate: naturally transparent and commonly used for medical tubing, this medical grade plastic features high tensile, shear and flexural strength. It also provides high heat resistance, low moisture absorption, and is stronger than acrylic.
  • PEEK: an exotic medical grade plastic resin that is highly resistant to chemicals, resists cracking and fatigue and can be sterilized via autoclave. It is FDA approved for food contact and has a UL 94 V-0 flammability rating.
  • Ultem™: used for medical devices and be sterilized via autoclave. It resists environmental stress and cracking, provides excellent dimensional stability and exhibits superior strength and stiffness.


We also use several specialized medical grade plastics with built-in resins and fillers, such as fiberglass carbon fiber, talc, or custom color compounds, to give the completed medical moldings mechanical advantages or other unique properties.


Medical Plastic Injection Molding in An ISO Certified Facility

Our expertise with engineering resins and specialized medical plastics ensures that your medical injection molding products will meet your exact specifications. We are ISO 13485:2003 certified for comprehensive quality assurance management in the manufacturing of medical devices.

Contact us with your design requirements and we will help you determine which medical molding process and material are best for your application. Some parts might not be suitable for medical injection molding and if that is the case, we will help you find a process that will work for you.

Our goal is to provide medical molding solutions that are within your budget while delivering products that meet the design requirements of your application. We also understand the importance of providing materials that are biocompatible and adhering to regulatory requirements for medical molding.

To complete your medical injection molding project, Stack Plastics provides various secondary services including:

  • Assembly using pneumatic or manual methods to join molded parts
  • Ultrasonic bonding to create a durable bond between two or more components
  • Pad printing to add logos, instructions and other designs on the surface of your molded parts


Contact Stack Plastics for Medical Injection Molding

Contact Stack Plastics for more information on our medical plastic injection molding and catheter molding services, or request a quote today.