Dielectrics brings decades of expertise in the welding and bonding of engineered thermoplastic materials to the manufacture of medical device products. This includes Radio Frequency (RF), Impulse, Ultrasonic, and Thermal welding, as well as Vacuum Forming, Sewing and Printing. Our real-world experience in their application enables us to perrform these capabilities without fail time and time again for our customers.
Welding and Bonding
As an established leader in thermoplastic welding and bonding for the medical device industry, Dielectrics is well known for its expertise in Radio Frequency welding (also referred to as "RF welding", "Dielectric sealing", "High frequency" welding, or "heat sealing"), a technology that uses electromagnetic energy to form a permanent bond that is as strong as the original thermoplastic materials. Additionally, Dielectrics has deep experience with Impulse welding, appropriate for applications requiring a lower seal bond strength; Ultrasonic welding, used in situations requiring very quick welding speed; and Vacuum Forming, which can be used for parts with complex shapes like packaging trays or medical bedding components.
In today’s hyper competitive world, time to market can be the difference between success and failure. Dielectrics has pioneered prototype tooling technology that enables quick turnaround of complex welded structures, frequently resulting in iterations that can be executed within a few days. Additionally, we offer dedicated lab, staffing, and design services to aid in the prototyping process and can create production representative models that can be used for both bench top and functional testing. These options allow you to economically and quickly arrive at final designs before committing to production tooling.
Equipment Design and Build
Throughout its history, Dielectrics has designed and built state-of-the-art thermoplastic processing equipment for our contract manufacturing clients. Many of our products require highly specialized manufacturing techniques, which in turn require upgrading or customizing equipment. This equipment may be utilized during all aspects of product development and commercialization to drive higher quality, increased output and lower unit costs. Our ability to design and fabricate high volume in-line and other cost reducing manufacturing systems using scalable, modular equipment design is bolstered by equipment specialties that include integrated production systems for RF/Impulse Welding, thermoforming, functional testing, filling (gels), printing, and die-cutting.