Few industries are as competitive and as dependent on producing quality
products while optimizing manufacturing costs and reducing time to
market as the medical industry. For over 30 years, Branson has provided
medical manufacturers with the tools they need - cost-effectively and
on schedule.
Medical device manufacturers are under tremendous pressure to bring quality products to market faster than the competition. This requires creatively compressing the development cycle and choosing an appropriate assembly process.
The challenge to perfect a final product presents numerous opportunities to improve the development process - from choosing the right assembly processes and creating a feasible part/joint design to optimizing process and operating procedures. Branson meets these challenges through the following plastics joining technologies:
Ultrasonic assembly is ideal for assembling all types of medical products, such as filters, instruments, fluid vials, masks, and surgical garments. Benefits:
Ultrasonics is fast. Welding usually occurs in less than a second.
It is clean, since no consumables are required, the risk of contamination is decreased.
Ultrasonics eliminates the costs of consumables, in addition to producing repeatable, error-free results.
Ultrasonic equipment is equally adaptable to cleanroom environments and high-volume production situations.
The benefits of hot plate welding for medical applications:
Hot plate welding consistently produces high-strength, hermetic seals that are particle-free. This is especially crucial in applications such as filters, manifolds, and pumps.
Hot plate welding can weld both curved joints and internal walls. It is excellent for assembling parts with exceptionally thin walls or complex geometries.
Vibration welding
Can weld irregularly-shaped parts, parts with odd geometries, and larger parts.
High-pressure hermetic seals can be achieved.
Process is not material sensitive
The Spin welding
Process is quiet
Fast cycle times
Equipment can be easily adapted to automation.
The Laser IRAM process has
Low particulate
Fast cycle times
Adaptable to cleanroom environments
Hermetic seals
Branson's technology can complement or replace your existing assembly techniques:
If you manufacture
Branson provides
If you manufacture
Branson provides
Filters using heat or solvents
Ultrasonic, vibration welding, spin, or laser IRAM welding
Fluid vials with heat or adhesives
Vibration or hot plate welding
Garments using thread or staples
Ultrasonic "sewing"
Tube sleeves fastened with adhesives or clips
Ultrasonic swaging
Devices requiring hermetic seals using adhesives
Ultrasonic, vibration, hot plate, or laser IRAM welding
Laproscopic and other rigid tube assemblies
Ultrasonic, spin, or hot plate welding (depending on thickness & material)
Surgical instruments assembled with solvents or screws
Ultrasonic, hot plate or vibration welding
Body fluid bags with heat or adhesives
Ultrasonic sealing
Pump filters
Anesthesia filters
IV fluid filters
Blood filters
Cardiometry filters
Diagnostic test filters
Cardiopulmonary filters
Oxygenator filters
Trocars
IV catheters & kits
Blood donation kits
Dialysis tubes
Vented spikes
Retracting needle shields
Tube & needle packaging
Subclavian catheters
Pipettes
Disposable garments
Body fluid bag covers
Transdermal patches
Electode patches
Hernia wraps
Hair & shoe covers
Waste bags
Masks
Gurney covers
Hook & loop straps
Leg & arm covers
Blood basins
Portable urinals
Testing trays
Pump cylinders
Urine meters
Peak flow meters
Vials
Drip chambers
Home testing kits
Culture flasks
Chest drainage units
Manifolds
Trumpet valves
Surgical staplers
Aspirators
Volumetric pumps
Insulin programmers
Laproscopic tubes
Neuro twist drills
Tumor markers
Surgical sponges
Profusion devices
Curvettes
Intraocular lenses
Artificial joints
Braces & splints
Sensor components
Fluid delivery systems
Dialysis systems
Colostomy/ostomy fitments
This table illustrates examples of materials that are commonly used in the medical industry and their suitability for each of our processes. It does not refer to the strength of the weld obtainable. We ask that you use this chart as a reference point only, as the success of each process depends on the application, as well as the grade of plastic and type and percentage of additives that are being used.
Due to the critical nature of medical manufacturing, we strongly recommend that you consult our applications engineers to discuss your application's design, materials and processes. Our applications laboratory maintains a database of successful applications. It is likely that we have experienced your application and materials before - ask us!
Material
Ultrasonic Welding
Linear Vibration Welding
Orbital Vibration Welding
Hot Plate Welding
Spin Welding
Laser IRAM Welding
ABS
E
E
E
E
E
E
Acrylic
G
E
E
E
E
E
Butadiene-styrene (K-resinR)
G-F
E
E
E
E
E
Nylon
G-F
E
E
--
E
E
Polycarbonate
G
E
E
E
E
E
Polyetherimide
G
E
E
E
E
G
Polyethylene
F-P
G
G
E
G
G
Polypropylene
F
E
E
E
E
E
Polystyrene
E
E
E
E
E
E
Polysulfone
G
E
E
E
E
E
PVC (rigid)
F
G
G
G
G
G
SAN
E
E
E
F
G
E
Key: E = Excellent, G = Good, F = Fair, P = Poor -- = Denotes unsuitability of process for material
Few industries are as competitive and as dependent on producing quality
products while optimizing manufacturing costs and reducing time to
market as the medical industry. For over 30 years, Branson has provided
medical manufacturers with the tools they need - cost-effectively and
on schedule. 
Pump filters
Trocars
Disposable garments
Blood basins
Trumpet valves
Intraocular lenses
