Freudenberg Medical showcases new solutions in two-component injection molding

Freudenberg Medical is presenting several developments that further expand two-component injection molding for medical technology. These include a hemostasis valve for the catheter sector, a hybrid component for analytical diagnostics, and a silicone belt for premature babies. All products are based on precise material combinations and are suitable for demanding clinical applications.

Freudenberg Medical two-component injection molding for customer-specific applications

Freudenberg Medical is showcasing a portfolio that ranges from customer-specific developments to its own product lines. The focus is on two-component injection molding, which enables the precise combination of different materials. The spectrum ranges from solutions for catheter systems to components that the company manufactures in-house. Close coordination between design, material selection, and the manufacturing process results in components that are designed for high mechanical strength, tight tolerances, and complex functional areas. One focus is on components that combine several material properties in a single process step. This process shortens workflows, reduces waste, and helps to achieve reproducible results for sensitive medical applications.

Hemostasis valve with soft and hard silicone components

A key product is a two-component hemostasis valve used in the catheter area. The design is based on two silicone components of different hardness. The softer component reliably seals blood vessels, while the harder component ensures structural stability. The aim is to prevent blood loss in both directions – both towards the conduit system and outside the body. The valve is used in procedures where hemostasis plays a central role. The integrated two-component process creates a component that does not require downstream assembly. This improves quality and enables uniform material bonding, which is crucial in safety-critical applications.

Hybrid component for diagnostics and oncological analysis procedures

Another component combines silicone with thermoplastic – a combination that is challenging due to the different material characteristics. Freudenberg Medical has developed a process for this that combines both materials in the same tool. The silicone component offers optical and flexible properties, while the thermoplastic serves as a carrier material. The component is used in analysis technology, particularly in diagnostic procedures in oncology. An integrated lens enables precise guidance of the analysis medium. Combining the materials in a single process step results in stable adhesion, better repeatability, and lower process costs. This has replaced previous multi-step processes.

Silicone belts for premature babies: a skin-friendly alternative to electrodes

Another focus is on a product for neonatology. Until now, premature babies have been monitored using electrodes that were stuck directly onto the skin. As the skin of premature babies is particularly sensitive, this often led to irritation. The newly developed silicone belt replaces these adhesive electrodes with a flexible, soft material that fits snugly against the body. The belt consists of several layers of silicone with a particularly soft feel and is additionally coated to improve skin contact. Inside is a flexible PCBA module that continuously transmits medical parameters to clinical monitors. The functionality corresponds to classic electrode technology, but without its disadvantages. The so-called kangaroo effect is also medically relevant: premature babies have been shown to develop better when they are physically close to their parents. The silicone belt enables this closeness without interrupting monitoring. The child can be taken out of the incubator and placed with the parents while all parameters continue to be measured stably.

Process integration: Two materials in one mold

The areas of application for the products are based on a uniform technological foundation. In two-component injection molding, two materials are introduced into the same mold either sequentially or in parallel. This creates a strong bond without additional assembly or bonding processes. This integrated manufacturing process increases dimensional accuracy, reduces sources of error, and enables cost-effective production even with high quality requirements.