Disposable COC components launched for wearable drug delivery devices

Plastikos, a custom injection moulder and its sister mould making company Micro Mold, have successfully commercialised disposable cartridge components made of cyclic olefin polymer (COC) for wearable drug delivery devices

Plastikos said it has commercial projects underway with US drug delivery device manufacturers and is also exploring uses for COC in other related drug delivery applications.

The precision disposable cartridges, which consist of several parts moulded of Topas COC from Topas Advanced Polymers, are manufactured under strict performance qualifications including highly challenging tolerance levels and multi-cavity tooling, according to Plastikos.

Rob Cooney, manufacturing manager for Plastikos, said: “In these highly demanding applications, we are able to push the limits in terms of precision moulding because of the broad material and process know-how we bring to the table.”

Plastikos’ project included the design and construction of multi-cavity moulds that range up to 32 cavities with fully interchangeable inserts among all cavities.

To mitigate the risk of shipping a single defective part, every cavity on each mould was designed and built with a cavity pressure sensor. This mould sensor technology is used to monitor every cycle in production and provides 100% traceability, according to the company.

Plastikos said it worked with Topas Advanced Polymers to produce complex geometries and tight tolerances down to less than 0.001 in. Topas COC provides purity, drug compatibility, biocompatibility and dimensional stability. The material delivers consistent, reproducible performance and facilitates miniaturisation of drug delivery systems.

Timothy Kneale, president of Topas Advanced Polymers, said: “We have worked closely with Plastikos for several years now and are very impressed with their ability to scale up incredibly precise designs to meet the needs of healthcare device makers.” 

Dan Snyder, technical sales manager for Plastikos, said: “Topas COC fills a vital role in the disposable cartridge because of its repeatable performance in an industry where precision means everything.

“It’s a well-respected material because of its drug compatibility and other high-performance attributes.”