To manufacture its UltraSafe Passive Needle Guards, Safety Syringes Inc. needed to find a material that was not only robust and transparent, but also offered improved flow, lubricity, and easy release characteristics. Bayer MaterialScience LLC met Safety Syringes' requirements with Makrolon Rx1851 polycarbonate, a low-viscosity resin with enhanced internal mold release technology that provides increased design flexibility for complicated parts.
"We chose Makrolon Rx1851 after materials testing, including functional testing and accelerated aging," said Fred Field, vice president, Research and Product Development, Safety Syringes. "Bayer MaterialScience LLC offered expert support throughout the molding trials and provided answers to our technical questions during the functional validations."
The product, a single-use, anti-needle-stick device for pre-filled injectable syringes, is composed of two telescoping plastic components and a spring. The body component of the device is injection molded using the Makrolon Rx1851 resin. "Unlike other products on the market, the device doesn't push the needle guard forward into the user, but rather allows the syringe and needle to pull away from the patient and into the guard," Field said. "This is especially important when one considers that an injury from a medical needle is reported every 30 seconds in the United States with potential dangers of infections, illness, and even death from accidental needlesticks."
"The lubricity of Makrolon Rx1851 resin was a key attribute for this needle safety device, which requires a durable, dimensionally stable material," said Kevin Dunay, consumer & medical market segment leader, Polycarbonates NAFTA, Bayer MaterialScience LLC. "Furthermore, the high-strength, transparent properties of the resin facilitate visualization of syringe markings, labels and contents while at the same time helping to maximize protection."
The medical grade resin is supplied in pellet form for injection-molded applications. It is available in clear tint as well as in other Rx Medical colors from Bayer MaterialScience LLC's LEDA compounded color technology, all of which meet U.S. Food and Drug Administration (FDA)-Modified ISO 10993, Part 1, "Biological Evaluation of Medical Devices" tests, the widely accepted standard for biocompatibility.