Case Studies

i-STAT Cartridge Base and Cover

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.



The Challenge

Offer a resolution for the issues with their previous supplier:

  • Help them reduce quality issues with supplied components
  • Improve delivery performance
  • Assist in design for manufacturability & final assembly

The Solution

Polymer provided the following to ensure the customer’s success:

  • Utilized our expert engineering services to improve component and device quality
  • Provided a quick, comprehensive & fully documented take-over tooling process for a smooth program transfer
  • Used scientific molding processes, high-tech machinery and talented employees, to help provide a reduction in their defect rates and a significant improvement in the overall quality of the finished assembly, now done in-house at Polymer Conversions
  • Implemented a kanban supply program to ensure on-time deliveries and supply chain security
  • Provided improvement suggestions for next generation products

PCI Sherwood Harsco Propane Tanks Gauges Callenge and Solutions

Sherwood Harsco Propane Tanks Guages

The Challenge

Find a way to reduce the cost of the Lense Dial Product. The systems must:

  • Help the customer remain competitive.
  • Help in their efforts to grow their business.
  • Increase the overall quality of the product.

Features of the part:

  1. The dial assembly has 4 different printed lense variations. These variations are used to accommodate different types of tanks, which indicate propane levels.
  2. The lenses are multi-colored (some 2 color, some 3 color). This allows the reader to quickly and accurately measure the level of each tank.
  3. Each pointer used per assembly has a magnet that is magnetized and 100% tested before final assembly.
  4. Dial assemblies are ultrasonically welded, welds are hermetically tested and each part is tested for proper operation before shipping.

The Solution

Polymer was able to suggest and implement the following to ensure Sherwood’s success:

  • Polymer engineers re-designed the assembly, converting 4 metal parts to 1 plastic part. In doing so, the accompanying operational steps were eliminated. The finished dial is now shipped as a complete assembly rather than separate components.
  • The suggestion by PCI to print graduations on the opposite side of the lense, eliminated the normal wear and tear that occurred out in the field due to external forces such as weather and nature.
  • Asking to move the full assembly from the customer’s location to ours, helped to further cut costs and allowed Polymer to utilize its full range of in-house capabilities.


Sensegard Hearing Protection

The Challenge

Keeping the customer as an industry leader and their business growing. Increase the overall quality of the product while keeping in-line with the following issues:

  • Safety: Loud damaging noise is suppressed.
  • Comfort: Less than 2 oz. and adjustable.
  • Quality: No distortion of sound; Block harmful noise but allows speech and other useful sounds to be heard.
  • Convenience: Folds for easy storage or can drop around the neck while not in use.

The Solution

Design Improvements and Cost Savings

PCI suggestions eliminated 2 molded components and one assembly operations.

Injection Molding

Scientific process monitoring and high-quality, precision molding improved part quality by 70% over our competitor’s efforts.

Complete Device Assembly

Polymer’s adjusted hermetic seal weld and high-tech machinery improved sound attenuation and device performance.

Final Consumer Packaging

We offered comprehensive packing services to optimize point-of-sale supply chain.