SURGICAL DEVICES
SURGICAL EYE CARE
INSTRUMENTATION
ENDOVASCULAR DEVICES
PRECISION MEDICAL INJECTION MOLDING
FOR SURGICAL INSTRUMENTS
At Plastikos & Plastikos Medical, we meet your surgical device manufacturing team where they are—then move together, fast and in-step. From surgical eye care to endoscopy, instrumentation, glaucoma, and vascular access, our partnership mindset keeps your project timeline at the center of our priority.
You’ll work directly with our degreed Plastics Engineers who listen first, shape DFM decisions with you, and stay close through build, sampling, and launch—so momentum never gets lost between handoffs. The result is a smoother design transfer, fewer surprises, and a trusted path from concept to production with a team that feels like an extension of yours.
HOW WE DELIVER
FOR COMPLEX SURGICAL INSTRUMENTS
MOLD FILLING SIMULATION
At Plastikos, we have a thorough understanding of mold-filling simulations to further optimize gate location, wall thickness, mold orientation, weld lines, etc. Our plastics engineering group will work with your device team to further improve potential issues through mold simulation.
MATERIAL SELECTION
Our Plastics Engineering team has vast experience working with many different types of polymers. In fact, we currently run over 100 unique grades of raw material. We will work with our customers to make recommendations based on device function, cost, and other key considerations to select the right material for the application.
ADVANCED METROLOGY
We utilize best-in-class metrology equipment, such as advanced CT scanning. This provides our customers with micron-level accuracy as well as non-destructive testing. In some cases, we can scan a full device and detect issues such as leak paths, assembly issues, and more.
CUSTOMER SPOTLIGHT
SURGICAL EYE CARE
A global leader in surgical and vision care products was searching for a molding partner that could deliver the intricacy and attention to detail their surgical eye care device required. The molding partner needed to have experience with specialty and engineering grade resins, expertise in developing complex, multi-cavity tooling as well as in-house tooling support with the ability to quickly react to changes during the development phase of their new device. Given the complexity of the device and a critical tolerance of less than 0.001″ on the fragile core pin in some applications, the customer was not certain that meeting such strict performance qualifications was even attainable. For this reason, they had elected to machine the component for many years, which became quite costly as volumes increased.
The Initial Challenge:
- Hold < ±0.001″ on core-pin-formed features across multi-cavity tooling.
- Mold engineering grade, medical resins (including filled grades) without generating particulate or knit-line weakness in load-bearing details.
- Validate under ISO 8 cleanroom conditions with full IQ/OQ/PQ and cavity-level traceability to de-risk field investigations.
- Convert from machined components to molding with measurable ROI in < 6 months.
Why it mattered: In the surgical field, dimensional creep on a core-pin feature can translate into misfit, increased actuation force, or abrasion, which can jeopardize the device’s performance.
OUR APPROACH (DESIGN-BUILD-RUN)
1) Core-Pin-Safe Tooling Approach
- Custom mold bases engineered for hardness; pocket and guide geometry tuned to minimize core-pin deflection under injection pressure.
- Micron-level cavity interchangeability with spare insert strategy; steel selection and coatings chosen to resist wear from filled resins.
- Optimized cooling to control warpage on thin-to-thick wall sections where DFM strategies could not be applied.
2) Simulation-Led Process Development
- Moldflow analysis to predict core pin deflection during mold filling. Multiple gates were required to reduce core pin deflection and maintain tolerance.
- Design Of Experiments (DOE) performed to create a robust process window.
- Decoupled II process strategy with eDART templates to lock pressure profiles for each cavity.
3) Mold Validation & Risk Management
- APQP-style phase-gate reviews with PFMEA/Control Plan alignment before OQ.
- Measurement strategy defined up front (CT scanning for enclosed features; optical/vision for cosmetics) with GR&R acceptance criteria.
STRATEGIC SUPPLIER PERFORMANCE
- 100% YEAR-OVER-YEAR ON-TIME DELIVERY PERFORMANCE
- ZERO YEAR-OVER-YEAR EXTERNAL REJECT RATING
- TENS-OF-MILLIONS OF PRODUCTS SHIPPED ANNUALLY
Customer Response
“Overall, Plastikos was an incredible find for us. There’s high comfort when selecting Plastikos for a new project as we know it will be done on time, done correctly and with high quality.”
— Teresa S., Purchasing Manager
DFM GUIDANCE FOR
COMPLEX SURGICAL DEVICES
- Avoid Blind Holes: Fragile core pins should pilot into mating geometry to provide stability during filling. A blind hole or core pin is susceptible to damage, especially pins under 0.020"
- Draft Where Possible: Draft should be considered on both internal and external geometry to avoid issues with ejection or cosmetic imperfections from the parts adhering to the cavity / core blocks.
- Utilize Mold Filling Software: Mold filling software can be an excellent tool to assess optimal gate location and predict outcomes such as core deflection, warp, pressure to fill, etc.
- Uniform Wall Thickness: When converting from machined plastic to injection molding, look for uniform wall thickness throughout. Also, some areas of the part may need core out to prevent extended cycle times or sink-related issues.
- Align Measurement Technique: Be sure to align measurement techniques with your supplier and try to avoid options such as pin gauging, as that can be subjective in nature. Preferred methods would include CT Scanning, CMM, or Vision Systems.
Contact Us
SCHEDULE A LIVE VIRTUAL TOUR
We understand the need to conduct your due diligence during the supplier evaluation process. To help maximize your time efficiency, we offer LIVE virtual tours at our customers’ request. We invite you to schedule a virtual tour at any of our manufacturing facilities.
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