The Challenge

Produce the i-STAT Cartridge Base and Cover component parts of a blood diagnostic system, the system must:

  • Utilize microfluidic and biosensor chip technology
  • Provide clinicians with a truly portable, nearly instantaneous blood analysis
  • Require only two drops of whole blood

The Solution

Polymer Conversions played a major role in developing the plastic parts that helped facilitate a diagnostic breakthrough using Mircofluidic and Biosensor Chip Technology.

Feature of the part:

  1. The puncturing barb is used to open a foil pouch of calibrant solution. It is molded with the overall height being held to within a tolerance of ± 001.
  2. There are a number of interchangeable inserts which make features on the part that hold the biosensor chips and code the device. These areas are molded flash free. Wall thickness in sections are molded down to .012 inches in Polycarbonate, ABS and PETG.
  3. The parts are molded basically sink-free and flat to allow for proper attachment to each other and have all the cleanliness requirements of a critical medical component.
  4. The zero-defect quality requirements necessitates the use of advanced methods such as SPC and a Hunkar CIM monitoring system. Molding process parameters are monitored and key product characteristics are recorded and available to the customer.

Polymer Conversions is a full-service Medical Injection Molding Contract Manufacturer that specializes in highly technical, tight tolerance thermoplastic tools, components, medical devices, assemblies and post molding applications. Read more of our medical injection molding case studies here.