Advanced materials for medical devices

The global medical plastics market is projected to exceed 10 billion pounds by the year 2015, according to the research conducted by Global Industry Analysts, Inc. The United States represents the single largest market for medical plastics worldwide. The country's demand for implantable medical devices is expected to rise by as much as 8% annually to hit $48 billion by 2014, according to Freedonia. Asia-Pacific constitutes the fastest growing market for medical plastics in the world. In terms of end-use segments, medical product components represent the largest and the fastest growing end-use segment as compared to medical packaging.

Recent development in medical plastics
Leading suppliers of material solutions are teaming up with manufacturers of medical devices to launch products that are aimed at improving safety and drug delivery. SensorMed has introduced a disposable version of its CableCap? laparoscopic safety device, which is designed to eliminate the risk of fire caused by high-intensity surgical light cables in operating rooms. The CableCap device is injection moulded of Udel? polysulfone (PSU) resin from Solvay Specialty Polymers for high heat resistance, strength, and excellent light dispersion.

The simple, one-piece oblong device, which has already received 510(k) clearance from the U.S. Food & Drug Administration (FDA) is designed with four molded-in fins for optimal light and heat dispersion. The CableCap inserts directly into the distal end of surgical light cables, and should be used at any point during minimally invasive surgery when surgical cables are not attached to scopes. CableCap effectively diffuses the energy generated by the light cables, making them cool to the touch and preventing the risk of burns and fires associated with these instruments.

Surgical light cables, which are part of the illumination system used during laparoscopic and endoscopic surgical procedures, can produce heat readings of approximately 450℉ (232℃) at their distal ends when hooked up to a standard 300-watt surgical light source, according to SensorMed. Dangers include an exposed cable coming in contact with patient drapes or other fuel sources such as alcohol-based skin prep agents, which can result in serious skin burns or O.R. fires.

After an extensive material testing evaluation, SensorMed opted for Udel PSU over a range of other thermoplastics due to its combination of thermal and light dispersion properties, according to William Milam, VP of Engineering at SensorMed. "The material's transparent amber colour offers an optimum balance in terms of light dispersion and heat absorption. A more translucent material would result in a brighter light that would potentially distract surgeons, whilstan opaque-coloured device would retain too much heat," Mr. Milam added. Udel PSU also withstands EtO gas sterilisation and is compliant with ISO 10993-1 for limited exposure, non-implantable applications. Eisertech LLC, another designer and manufacturer of costeffective spinal implants, introduced its new cervical cage and lumbar cage implants made of Zeniva? polyetheretherketone (PEEK) rods from Solvay. Zeniva PEEK – part of Solvay's line of Solviva? Biomaterials – has a modulus very close to that of bone plus excellent toughness and fatigue resistance.

The cage systems, made from various sizes of Zeniva PEEK rods, are hollow so that bone can grow through the device, fusing the adjacent bony surfaces of the vertebrae. "Zeniva PEEK delivers the high-performance properties that are necessary for a high-precision implant used in cervical spine fusion surgery," said Lukas Eisermann, president of Eisertech.

Zeniva PEEK offers numerous advantages over metals such as titanium for these intervertebral implantable dNike Air Penny 5