Plastics News
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“The innovation portfolio for the future is looking very different from 10 years ago,” said Greg Nelson, senior vice president and chief technology officer at Eastman Chemical Co. in Kingsport, Tenn.
“It is the fuel of our growth to replace materials with materials that are sustainable” and offer less risk. “We are driving in that direction.”
“We continue to look to develop materials and technologies for more demanding applications,” Larry Johnson, health-care marketing director for PolyOne Corp. in Avon, Lake, Ohio, said at the Feb. 9-11 show.
For example, PolyOne’s GLS thermoplastic elastomers business introduced a clear Versaflex HC TPE for medical tubing. The new TPE augments five medical grades of the material introduced a year ago that are phthalate- and halogen-free and can be extruded or injection molded, allowing the same material to be used in tubing and connectors.
Teknor Apex Co. in Pawtucket, R.I., and Vesta Inc. of Franklin, Wis., also introduced tubing innovations at the Anaheim show, aiming for increased shares in the medical tubing market, which uses 400 million pounds of material annually in the U.S. — 80 percent of it PVC.
Teknor Apex unveiled its Medalist MD-500-series compounds that it said are the “first fully practical alternative to PVC” for many tubing uses. Vesta introduced its non-metallic-reinforced, kink-resistant tubing that has silicone inner and outer layers and can currently be used in tubing applications with inside diameters of 1-6 millimeters. “It is kink-resistant, has increased burst pressure and uses a two-step manufacturing process that makes the manufacturing of catheters more efficient,” said Bill Woinowski, Vesta’s research and development manager. “I think we can manufacture it in sizes as low as 0.05mm.”
This technology, he said, offers a cost advantage over current designs while improving product performance and reducing the risk of failure. The tubing, which has been in development for a year, “opens a few more doors” because it can be used in any application “where the tubing has to take a tortuous path.”
“When you start talking about larger size and thinner-wall applications, we feel it has great potential,” he said. Potential uses include anywhere tubing is part of a flow-control system, connecting tubes, access devices, suction devices, and breathing, vas- cular and draining tubes.
Teknor Apex said its Medalist MD-500 compounds are an alternative to PVC tubing, which often contains DEHP — di(2-ethylhexyl) phthalate.
“Through no fault of the phthalate family of plasticizers for flexible PVC, market interest in replacing them is rapidly mounting in Europe and North America, particularly in the medical-device sector,” said Peter Galland, industry manager for the vinyl division of Teknor Apex. “Mounting opposition has device manufacturers scrambling for alternatives.”
With that in mind, Teknor Apex introduced its new “non-vinyl material for tubing,” which delivers PVC-like performance, according to Elliott Pritikin, new-business development specialist in Teknor Apex’s TPE division. “Clarity and kink-resistance have been a real hurdle for non-PVC materials, but we have developed that with our new material,” which he said is clear and has enhanced sterilization resistance.
In addition, he said Teknor’s new Medalist MD-500 compounds “can be sterilized using both the ethylene oxide sterilization process and gamma irradiation with the resulting color change equal to or less than vinyl materials.”
Pritikin said potential applications include infusion tubing, respiratory tubes, feeding tubes and peristaltic tubing.
‘We aren’t going after PVC tubing applications,” Pritikin said. “We are offering an alternative to someone wanting to go away from PVC” because of concerns over phthalates. “We are in position to support PVC and non-PVC.”
“There is a lot of negative perception of PVC among the public,” added Nick Sandland, senior market manager for medical products in Teknor Apex’s TPE division. “And sometimes perceptions dictate reality.”
Tubing wasn’t the only area where new innovations surfaced.
Sabic Innovative Plastics US LLC introduced three additions to its LNP Stat-Loy specialty compound line that have “permanent anti-static properties” and are targeted toward drug-delivery applications, said Tom O’Brien, product marketing manager for health care at Sabic IP. “They are aimed at improving the efficiency of [delivery devices], whether it is an inhaler or pill counter.
“Drug manufacturers and distributors want to ensure they are giving out the right amount of medication and this will enable them to do that,” said O’Brien. “Static electricity is a major challenge in the effective use of inhalation devices because tiny drug particles can build up electrostatic charges that cause them to adhere to the device instead of being dispensed to the patient. These compounds provide permanent anti-static performance” to prevent that.
O’Brien also said Sabic continues to work on providing materials that allow thinner walls for housings but retain the same impact resistance, and to develop materials that can make medical products and devices smaller and more portable.
“With home health care, things are getting smaller and more portable,” O’Brien said. “And with more products now going home with the patient, materials have to be more chemical-resistant because you don’t know what people will be using” to keep them clean. “The products become a piece of furniture” and must satisfy that concern as well, he said.
“The medical industry needs to create designs that connect with the patient, and put parts in front of humans that make them feel human,” agreed Nelson of Eastman Chemical, which announced at the show a partnership with DD Studio in Carlsbad, Calif., to develop and design potential medical applications that are focused on such innovations.
“It has grown more important for materials suppliers and designers to work together,” said Scott Hanson, global industry leader for the medical market segment of Eastman’s specialty plastics business. “Through our collaboration, we can help designers who are creating state-of-the-art medical devices to bring them to market easier and faster, and also consider next-generation materials to solve industry issues.”
Eastman also unveiled MP100, a new grade of its Tritan copolyester aimed at rigid medical packaging markets, following on the heels of its introduction of Tritan for medical applications a year ago.
“Tritan solves some problems the industry has had with parts fracturing in packaging, because it is more resistant to drop-impact,” said Hanson. “Tritan retains its toughness over a longer period of time” than other materials,” he claimed. “It fills a high-performance need for medical packaging.”
In addition, because of Tritan’s temperature resistance, companies that want to sterilize at higher temperatures can save money because they can speed up the ethylene oxide sterilization process.
“Using Tritan for packaging also allows customers to reduce secondary processes and eliminate foam inserts and cardboard packaging, further reducing their costs,” Hanson said.
Eastman also displayed a prototype of a double-dose cup that showcased the ability to join Tritan parts together, without adhesives or fasteners, using a technique known as cold swaging. The technology, developed for Eastman by DD Studio, lets part designers and fabricators bend, crimp and fasten two plastic parts together in a watertight seal using their natural friction, avoiding the use of chemicals, adhesives and mechanical fasteners.
Critically, the process also “cuts the cost of manufacturing, improves the ease of assembly” and enables the same part to be made with both thick and thin sections, said Hanson.
“I expect there will be some announcements this year” regarding the use of Tritan in several medical applications — possibly in areas such as fluid management and intravenous components or containers, said Hanson.
The key to the future, Eastman’s Nelson said, will be to help medical providers minimize hospital-acquired infections, cut costs and reduce the use of resources. “We all need to lower our footprint,” he said. “Tritan will be a key enabler for that.”
Other product introductions at the show included:
* A single-use, anti-needle-stick device for pre-filled syringes from Safety Syringes Inc. made from Bayer MaterialScience’s Makrolon Rx 1851 resin.
* New elastomer-derivative, performance-enhancing materials for catheter tubing from Clariant International Ltd.
* Twelve new grades of engineering polymers from DuPont Co. with lower material density that make it easier to form geometrically complicated parts and also help minimize finishing operations.
* An expansion by PolyMedex Discovery group of its NanoMed nanoparticle technology to include thermoplastic formulations for the minimally invasive device market.
* New TPE compounds from Teknor Apex that the company claims have double the adhesive strength of standard TPEs when over-molded onto high-density substrates; as well as a new gamma-stable rigid PVC injection molding compound with the strength and clarity needed for tubing connectors, luer locks, valves, drip chambers and instrument handles.
* Bayer MaterialScience’s new brand name, BayMedix, for its medical products, coatings, adhesives and custom compound formulations.
Eastman Collaborates with DD Studio
EASTMAN CHEMICAL COMPANY COLLABORATES WITH DD STUDIO TO ADVANCE MEDICAL-DEVICE DESIGNNew double-dose cup showcases cold swaging attribute of Eastman Tritan™ copolyester
Kingsport, Tenn. — Feb. 10, 2010 —
Eastman Chemical Company and DD Studio announced a collaboration to advance strategic, human-centric innovations for the medical market and unveiled a double-dose cup that showcases the breadth of design and processing possibilities of Eastman Tritan™ copolyester at the Medical Design & Manufacturing West (MD&M West) trade show Feb. 9 to 11, 2010, in Anaheim, Calif.
“As the medical marketplace increasingly values safe, durable and reliable devices that make an emotional connection with users and recognizes design as a competitive advantage, it’s grown more important for materials suppliers and designers to work together,” said Scott Hanson, global industry leader, medical market segment, Specialty Plastics Business, Eastman. “Through our collaboration, we can help designers who are creating state-of-the-art medical devices to bring them to market easier and faster, and also consider next-generation materials to solve industry issues.”
The double-dose cup designed by DD Studio using Eastman Tritan™ copolyester is composed of individual pieces that create a functional medical cup when assembled. The attributes of toughness, clarity and chemical resistance make Tritan ideal for the design and development of intricate and complex medical devices. The design flexibility and ease of processing of Tritan also make it a material of choice for prototype development.
During creation of the double-dose cup prototype, DD Studio discovered Eastman Tritan™ copolyester also is ideal for cold swaging, a joining technique that offers unique possibilities to part designers and fabricators. The method involves bending and crimping a plastic part without heat to join two parts, which can save energy and avoid the use of chemicals, adhesives and mechanical fasteners. Tritan offers a tight, smooth and continuous fit between two parts, and provides product manufacturers and designers with an innovative, advanced material choice.
“In 25 years of developing new products, Eastman Tritan™ copolyester is the first material DD Studio has discovered that offers all of the characteristics required to specify it universally,” said Michael Swartz, growth strategist, DD Studio. “We’re inventing new products and processes — entering spaces that have yet to be explored. By working with Eastman materials, such as Tritan, we’re able to press the limits of possibility while validating our capacity for successful manufacturing.”
The double-dose cup is the first of many samples that will be developed using various Eastman resins to encourage interaction and spur design and engineering innovation. Medical grades of Eastman Tritan™ copolyester, which were launched into the medical market during MD&M West in February 2009, provide outstanding lipid and chemical resistance; higher heat stability; excellent long-term clarity; added durability and toughness; and are manufactured without bisphenol-A (BPA) or halogens.
During MD&M East in June 2009, Eastman launched a new family of blends based on Eastman Tritan™ copolyester, marketed within PolyOne’s Trilliant™ HC specialty blends portfolio in North America. At the same time, Eastman also introduced a new high-flow, medical-grade polymer — Eastman Tritan MX731 copolyester — to its existing family of medical-grade copolyesters.
For more information on Eastman Tritan™ copolyester, visit www.eastman.com/tritan.
For more information on DD Studio, visit www.ddstudio.com.
For more information about Eastman and its products, visit www.eastman.com.
About Eastman Chemical Company
Eastman’s chemicals, fibers and plastics are used as key ingredients in products that people use every day. Approximately 10,000 Eastman employees around the world blend technical expertise and innovation to deliver practical solutions. The company is committed to finding sustainable business opportunities within the diverse markets it serves. A global company headquartered in Kingsport, Tennessee, USA, Eastman had 2009 sales of $5 billion.
About DD Studio
DD Studio, based in Carlsbad, CA, is a turnkey product development resource focused on profitable growth through user-centric design. Offering an impressive array of seasoned multidisciplinary specialists, DD Studio is a competent partner that serves as an extension of your own team. Specialized in the commercialization of technology, DD Studio has 25 years experience in the successful development of design and industry award-winning products — all finely tuned for cost-effective manufacturing. In the healthcare industry, the company develops laboratory instruments and medical devices across a broad spectrum of research
Plastics Today
Eastman to announce design collaborationBy PlasticsToday Staff
Published: January 14th, 2010
Eastman Chemical Co. announced that it will launch a design collaboration with DD Studio in San Diego, CA during the MD&M West show in Anaheim, CA (the co-located event, including Plastec West, is produced by PlasticsToday parent Canon Communications LLC). DD Studio is a leading design thinking and product development firm, said information from Eastman.
During the show, Eastman will also introduce expanded capabilities of its polymer portfolio for medical packaging and will participate in the show’s Innovation Briefs Theater with a presentation on polymer technology for medical devices.
Eastman is working with DD Studio to explore strategic, human-centric innovations for the medical market and other industries. Through the collaboration, DD Studio and Eastman are working together to investigate new medical-device applications for Eastman Tritan copolyester. The companies will unveil a new medical device that showcases the breadth of design and processing possibilities of Tritan, said Eastman.
“By pairing DD Studio’s forward-thinking, creative design process with Eastman’s material and technical insights, this collaboration offers innovative, quality solutions to practical design needs,” said Scott Hanson, global industry leader, medical market segment, Specialty Plastics Business, Eastman. “We look forward to continuing to work together to provide medical-device manufacturers with design and material insights.”
Bridging the gap from potential to reality - North County Times
CARLSBAD - A lot of hard work comes between getting an idea for a product and actually selling it. September 5, 2009. BRADLEY J. FIKES
Bridging that gap is what keeps DD Studio in business.The privately held company has handled nearly every facet of product development, from technology research to prototyping, usability studies and pricing components.
Customers include startups and large corporations, said Michael Swartz, DD Studio's growth strategist. Some just want help with external appearances on a nearly finished product, while others work with the company almost from the beginning.
"The types of work that we do vary from cosmetic design to very detailed engineering, solving a lot of engineering problems," Swartz said.
Prices start around $150 an hour, varying with the complexity of the project.
Visitors walking through the front door can see the results on wall displays or on the floor. There's consumer electronics, medical devices and home appliances. High walls with posters and large windows add to the creative atmosphere.
In the back of the company's sprawling headquarters just north of McClellan-Palomar Airport, there's the industrial workshops and machines that make conceptual models and functional prototypes.
Pointing to a spa control panel designed by DD Studio, Swartz said it presented significant engineering hurdles, such as making it waterproof and resistant to chemicals and exposure to ultraviolet light.
On the design end of things, he said, the controls had to be made "simple and intuitive."
The company's work has won it recognition from Connect, a San Diego-based nonprofit that encourages technology-based innovation.
In 2004, DD Studio won a Most Innovative New Product award from Connect. It was for designing the Ophthonix Z-View Aberrometer, a new system from Vista-based Ophthonix, for more accurately measuring eyes for corrective lenses.
In 2009, the company was a finalist for Connect's International Design Excellence Awards. That was for designing the Vue Personal Video Network, a wireless video monitoring system. Vue's egg-sized and roughly egg-shaped cameras can be mounted nearly anywhere.
In that case, the company's job was to help adapt an existing business video monitoring system to a home system the average consumer could use, Swartz said.
"What we came up was this metallic half-dome with a magnet, so you can just use an adhesive tape and stick these anywhere you'd like throughout the house," Swartz said. "You can put these in nearly any position."
In another job, for Carlsbad-based PhotoThera, the company designed positioning guides for the company's medical lasers. The lasers, aimed through the scalp into the brain, appear to stimulate a chemical reaction that helps some stroke patients.
At first, the idea was to make a helmet with holes where the lasers would be positioned, Swartz said. Instead, DD Studio developed a metal mesh with larger holes where the lasers can be positioned. The mesh collapses flat, which makes it possible to store more of them in the same space, saving money in shipment.
Industrial Design Excellence Awards
Industrial Design Excellence Awards - DD Studio Selected as Finalist - May 27, 2009
VUE Personal Video Network, designed by DD Studio has been selected as an IDEA finalist. Winners will be announced in BusinessWeek on July 17, 2009.
Tech Firms Fill Eternal Demand for Health Care Products
San Diego Business Journal, June 1, 2009TECHNOLOGY: Devices Include Surgical and Visual Aid Tools, Speech-Recognition System
By MARK LARSON
Technology firms making medical devices in San Diego, across the country and globally these days are in a position other tech-developing firms envy. They’re selling products into the health care consumer industry. Unlike other markets, healthcare has remained bulletproof during the downturn, and continues to demand new products.
Last week, the Business Journal talked to three small, locally based technology development firms about their latest market-driven innovations, aimed at niches where they see demand.
Carlsbad-based DD Studio is a 25-year-old industrial design firm. With 20 employees, it specializes in developing commercializing technology for its clients in the wireless, medical, life sciences, consumer products and government/military industries.
“We focus heavily on medical devices and laboratory instruments,” says Michael Swartz, the company’s Director of Growth Strategy. Among the products the company is developing is a tool to help first-response emergency medical technicians better treat heart attack victims to increase their chances of survival. Another project involves new design for a family of spinal surgical tools.
“We conduct user research to identify key opportunities in usability and human factors,” says Swartz. Recent research programs include shadowing of EMT’s, interviewing hospital personnel, and observing surgeries to uncover new design opportunities.
Now there’s demand for making medical devices usable at home by consumers, he says, and not just by doctors. Our research efforts ensure that vital needs are met, improving the adoption rate and general success of the new product.
DD Studio builds prototypes of new products it develops on-site, adds Swartz, so that all the manufacturing bugs are worked out before a new product is sent to a contract manufacturer for mass production.
The company has eight new product releases set for this year, with another six to eight in its development pipeline. For the past 10 years it has had well-recognized clients such as Hewlett-Packard, satellite services provider Hughes Network Systems, and DirecTV. Another big client during the past four years has been IGT, the large manufacturer of gaming machines. Others include Qualcomm, Kyocera Wireless, Hoist Fitness Systems, Rockwell Collins, Avaak and Sony.
Last year, DD Studio posted $3.8 million in revenue, and this year is on track for $4 million, says Swartz, noting the company has been profitable for more than 10 years. He declined to specify profits…