Most of the new materials on display at the MD&M West show in Anaheim, Calif. last week were developed to fight disease, especially the infections that hospital staff and patients are getting in large numbers. Many of the new plastics have been developed with antimicrobial properties.
Nearly all of them also deal with the harsher chemicals used today for disinfecting surfaces. In the fight against hospital-acquired infections, these harsher chemicals can damage plastics and other surfaces of medical equipment housings or enclosures not made to withstand them, Bruce Fine, Bayer MaterialScience's market segment leader for medical and consumer products, told Design News. The result can be unappealing surface changes, and worse, stress failures.
Plastics suppliers are also getting more requests for their materials to survive various sterilization environments. This year, many of the materials I saw on the show floor can withstand multiple sterilization processes, including those that depend on high-temperature steam, chemicals, gamma irradiation, or chemical methods.
DuPont Performance Polymers is getting more inquiries for information about materials content, due to more awareness of regulatory information, Diana Salvadori, North America healthcare manager, told us. There's also more concern among molders and OEMs about change management in all stages of the supply chain. Changes in raw materials content, additives, or manufacturing processes at the raw materials supplier can mean further testing will be needed downstream, she said.
Click on the image below to see some of the innovative materials introduced on the show floor.
The successful placing of catheter-based medical devices such as angioplasty, stent placements, and thrombectomy need variable stiffness combined with as much flexibility as possible. Those are two opposing needs, but Solvay has achieved this with its Radel polyphenylsulfone (PPSU). The material is being used by RiverTech Medical in one layer of that company's precision micro-tubing with variable flexibility for catheter-based medical devices. This microtubing, shown here, offers two to three different stiffnesses and flexibilities in a single component, Maria Gallahue-Worl, global business manager for healthcare in Solvay's specialty polymers division, told Design News.
RiverTech Medical made the micro-tubing with multiple layers of different polymers, plus a layer of woven wire material for reinforcing tubing walls. Radel PPSU provides strength and stiffness as the top layer, which is 0.002 inch (0.00508 cm) thick. The polymer's strength and melt processability are comparable to those of competitive materials like polyimide, and it can endure more than 1,000 cycles of steam sterilization without a significant loss of properties.
I was surprised at how much more these materials, especially the plastics, are doing this year compared to last year's show. Last year most of the new lines were antimicrobial and could withstand one sterilization process. This year, they're antimicrobial and can withstand multiple sterilization processes, plus harsher cleaning chemicals.
Interesting slideshow, Ann. I think it's interesting to note the evolution of these type of products, as you do here. I knew about antimicrobial medical materials but didn't know about the rest. It's an important area as well, given that these superbugs that develop in hospitals are the cause of death for a lot more people than one would think.
The whole hospital-acquired infection (HAI) thing has a lot of people in hospitals running scared. As you can see, it's even an "official" acronym now, at least among suppliers to hospital managers. I also learned, as a side note, that not only patients but also staff are catching some of these super-bugs. What I find interesting is how long we've been hearing about this problem. I think it's at least a decade now.
Great in-depth look at the show's materials, Ann. Yes, materaisl are doing more this year. I was amazed to see how many materials are now being displayed that are sufficiently compatible for implanation in the human body.
Thanks, Chuck. As you can see, most of them are plastics. So it was interesting to talk to Morgan Advanced Ceramics, which does ceramics and metals. I agree, though, there seemed to be a lot more materials that are being designed for either implants (29 days and more attachment or insertion) or short-term attachment (<29 days).
Ann your this effort is keeping us posted with the new stuff available. In this field it helps me discuss with the doctors for patients and staffs health as one of my subsidiary makes hospital supplies. Thank you and salute you.
I know what you mean, Ann. I am lucky enough so far not to have ever been in a hospital overnight but for years if anyone in my family has ever been, their loved ones worry that they would get sicker rather than better. I actually have a bit of a fear of being in a hospital for this reason. It's good that after all this time something is finally being done to combat these superbugs.
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
SABIC's lightweighting polycarbonate glazing materials have appeared for the first time in a production car: the rear quarter window of Toyota's special edition 86 GRMN sports car, where they're saving 50% of its weight compared to conventional glass.
Design engineers play a big role in selecting both suppliers and materials for their designs. Our most recent Design News Materials Survey says they continue to be highly involved, in some ways even more than the last time we asked to peek inside their cubicles.
Daihatsu is one of the first carmakers to customize car exteriors using 3D printing's mass customization capabilities. Effect Skins -- small exterior bumper and fender panels in different colors and textures -- can be ordered for its Copen convertible.
Several new products in this group of new adhesives, coatings, and sealants are formulated to protect sensitive electronic components, or to seal components of commercial and military aircraft. Others are designed to operate in tough, messy, dirty oil & gas operations, or for rotary applications and motors.
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