IDC examines Plastics in Medical devices at PDM 2010

The international product development agency, Industrial Design Consultancy Ltd (IDC), was selected to discuss the merits of plastics in design innovation as part of the speaker programme at this year’s PDM show in Telford 18-20 May 2010.

IDC’s managing director, Stephen Knowles, addressed the role of plastics in medical design drawing on the company’s varied international case studies.

The presentation highlighted a range of factors affecting plastics choice in product design when developing a world class medical device. Addressing the essential issues of device application and risk classification, as well as regulation, testing and compliance, Knowles looked at several award-winning medical products designed by IDC to illustrate how to tackle the central points in the process.

“Plastics often open doors in product design; choosing the right material is key to making a great product and can often prove cost-effective over other options. But it is only through an in depth understanding of polymers in the context of medical classification and regulations that superior quality products can be designed,” explained Knowles.

One product design placed under the microscope was a multi-award winning insulin pen designed for Indian healthcare giant Wockhardt.   With diabetes a significant problem in India, Wockhardt was able to supply insulin but lacked a cost effective way to administer it. The company needed both a disposable and reusable injector pen made all in plastic which would meet stringent international regulations (ISO/FDA), testing and compliance, and also side-step existing patents without compromising on quality.

“As with all medical device projects, understanding a product’s purpose and function, and identifying competing products in the marketplace is vital through in depth user research.  Scrutinising everything from weight and strength for durability, specific or unusual aspects of mechanical performance, resistance to oils, UV, solvents, radiation and so on, is all part of the process when choosing the best polymer for each job.  The question of sterility and medical classification is another major issue, drawing attention to cleanliness in manufacture as well as infection control. Yet, depending on the level of invasiveness, sometimes a medical device won’t even require a medical grade polymer. All these factors, as well as tooling and manufacture, are part of the process for the designer,” continued Knowles.

Several other successful medical devices designed by the in-house team of engineers, designers and model-makers were examined to illustrate the product development process.  The world’s first non-invasive Medick Personal Heart Monitor (class 1), from concept to production, and the ZYDUS CADILA Asthma Inhaler (class 2a), which has sold in the millions across India, are just two further examples of the merits of plastics in innovative design which IDC discussed on the day.