Forefront Medical Technology

Case Study: Specialty Pharmaceutical Bottle Production

_S3A0089.jpgMaterial choices often have impact on preferred production processes. Selecting a contract manufacturer capable of supporting a broad range of production options helps ensure the optimum process is utilized. In this case study, a customer wanted a pharmaceutical bottle made of a flexible, medical grade PVC material developed and manufactured. While blow molding is the preferred choice for bottles utilizing low density polyethylene, the flexible PVC material required an injection blow molding process. The team at Forefront Medical Technology was able to design and construct a mold and machine to meet the requirements.

The Challenge

The customer provided a 3D CAD model of the bottle. Forefront Medical’s engineering team selected an injection blow molding process as the option best meeting the customer’s requirements. There were several advantages with driving this choice:

  • Quality and repeatability
  • Cosmetic factors
  • Cost effectiveness.

Read more

Case Study: Specialty Drug Delivery Systems

Development of specialty drug delivery systems requires both strong materials and mechaniFFPS-193cal engineering expertise. And, in some projects there can be additional constraints tied to existing supply chains or preferred materials. This white paper looks at the process Forefront Medical Technology used in designing a Class III drug delivery system used in a chemotherapy application.

In this case the customer was a Tier One contract manufacturer, who built specialty kits for an original equipment manufacturer (OEM) of specialty drug delivery systems. The contract manufacturer was looking for a medical disposable manufacturer in Asia who met FDA regulatory requirements and could supply required components for their production operations using OEM-specified materials. The contractor also wanted the supplier to provide long-term cost reductions in line with the OEM’s requirements.

The Challenge

The customer provided the basic design for the mechanism and the components. The key design challenge involved identifying materials that met the customer’s requirement of Di 2-ethylhexyl phthalate (DEHP)-free and had the required bonding strength among components and tubes. This was complicated by the fact that one component supplier had been previously selected by the OEM and any design modifications would need to incorporate that component and supplier. Read more:


Key Issues in High Cavity Mold Design

_S3A0331 - Version 2One of the key challenges facing medical device manufacturers is determining the optimum mix of mold cavities and machines. High cavity molds enable medical manufacturers to tap economies of scale when fabricating high volume single-use products by reducing the number of machines needed to achieve required production volumes. However, increasing the number of cavities also can increase the project complexity. Forefront Medical Technology recently designed a 64-cavity mold for a customer. This case study looks at the challenges and lessons learned in the project.

Read more here.



Case Study: Redesign to Improve Product

_S3A0114.jpgA manufacturer of products used for foreign particle management in the esophagus found that the market for its product line was no longer growing. The Company decided that a redesign of the product line was the best way to increase market share.

They turned to Forefront Medical Technology for a solution. Forefront’s team recommended converting the manufacturing process used for the tubing from a dipping process to the combined use of extrusion molding and injection molding. The team also recommended changes in the materials composition for other components used in the product. This case study discusses lessons learned in the redesign and qualification process and the overall results. Read more.


Replacing Metal Components with Single Use Precision Molded Plastics

Metal parts are typically used in invasive medical equipment because a machined metal part ensures a tight seal at joints. However, use of metal components can increase cost over the life of the product when sterilization costs are considered. Additionally, even with sterilization, reuse of components exposed to bodily fluids and tissue can increase risk of patient contamination. Single-use precision molded plastic components offer a potential option for mitigating the contamination risks and eliminating the need for a washing/autoclave process, but molding these parts with enough precision to achieve the same performance properties as their metal counterparts has been challenging.

Forefront Medical Technology’s solution to this challenge is featured in Medical Design Technology. Read more.

Five Reasons to Select a Contractor with In-House Tool Design

To some, tooling may appear to be simply one more non-recurring engineering (NRE) cost in a product development process. However, in medical disposables manufacturing, it is also the single most important item in ensuring that quality and cost objectives are met. The quality of the tooling design and fabrication process dictates the amount of secondary processing options needed for the product, the contractor’s ability to control key parameters in the process likely to affect product quality, production throughput and the life of the tool. Is there an advantage in selecting a contractor with in-house tool design capability rather than a utilizing a separate tooling manufacturer? This paper looks at five reasons why the answer to that question should be “yes.” Read more:

Keys to Success in Medical Micro Molding

It’s no secret that medical devices are getting smaller. Implants, tubing and drug delivery systems now often require injection molders capable of fabricating parts at a micro level. The smaller the part; the more complex the injection molding process since material behaves differently in smaller shot sizes. Forefront Medical Technology, a specialty contract manufacturer with a focus in disposable diagnostic, drug delivery systems and medical device systems, has experience with both standard and micro molded products. Our white paper, Keys to Success in Medical Micro Molding, describes the product development and process complexities found in micro molding in greater detail, plus looks at how these capabilities were successfully applied in a recent micro molding project. Read more.