There are essentially two areas where polymers are used in the medical sector : disposable products/packaging products and medical devices. The disposable products or packaging products need lesser properties or performance compared to the sector of medical devices. New research and innovations play a major role in the field of medical devices where newer materials are required for better performance. To develop effective and safe devices, design engineers and manufacturers must have access to precise information on material properties. Several new materials with enhanced properties have been introduced:
Recently a self-bonding silicone rubber that improves product performance and custom thermoplastic elastomers (TPEs) with enhanced oxygen-barrier properties has been developed. BioSil SB self-bonding silicone rubber that bonds to thermoplastics reduces scrap and can enhance the overall performance of medical parts made from multiple materials. A two-shot moulding capability enables the silicone to be efficiently processed with substrate materials such as polycarbonate, PEEK, polyester, polyamide, and phenolic polymers. The co-moulding process eliminates the need to mould the silicone and thermoplastic parts in separate operations and manual assembling. Moulding a multimaterial part in one press, under one process, provides design engineers with greater design freedom compared with other methods. Seals, caps, septums and soft-touch instruments are among the medical applications suited for this moulding process. The technology is suited for any silicone and thermoplastic device component that is typically assembled or over moulded, as well as designs that demand complex assembly.

Initially engineered for food packaging, custom-formulated TPEs may also have a future in healthcare applications. These materials are reported to provide 10 times better oxygen-barrier performance, better clarity and cleanliness than conventional TPEs. Cleanliness is ensured via elimination of the leachable halogens and heavy metals used to cure thermoset rubber. The products offer numerous advantages over thermosets and silicone, which have traditionally reigned as the materials of choice for barrier applications. Silicone, despite its rubbery properties and clarity, is a poor material for barrier applications. Owing to their inert nature, TPEs can be used for tubing applications and can act as a substitute for silicone. To improve barrier properties in devices, design engineers could use TPEs in lieu of silicone and butyl rubber. Butyl rubber and TPEs share similar barrier properties but TPEs do not require multiple production steps.
Because TPEs can be processed by means of high-pressure injection moulding, extrusion, and blow moulding, TPES provide a great deal of design flexibility because. They are thermoplastics & can be converted by extrusion, injection moulding as well as blow moulding. TPEs do not require reinforcing fillers, thus allowing them to maintain low specific gravity and clarity. Moreover, they can bond to PP substrates, which open up opportunities for part consolidation and design innovation.

Another recent product introduction is of special interest to OEMs that manufacture diagnostic catheters and similar devices that require a smooth surface and radiopacity. Tungsten-filled thermoplastic urethanes, nylons, olefins, and other polymers are now available. The materials resist solvents, soften at body temperature, and have high specific gravity. They are available in Shore hardness ranges from 75A to 75D.