Your Silicone Solutions Partner

Bentec Medical combines its extensive silicone material science engineering expertise and breadth of silicone fabrication capabilities in order to develop the optimal silicone solutions for our medical device OEM customer base.  We don’t just fabricate parts as a “build to print” supplier, but we will also provide design consultation, select the optimal fabrication process to meet the needs of your product, build sub-assemblies or finished devices on a turn-key basis and assist with regulatory testing and documentation.

Our industry-leading breadth of silicone fabrication capabilities include the following:

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Molding

With a variety of state-of-the-art molding presses, Bentec Medical has the option for utilizing the optimum molding method for your product design and budget.  We use the following methods for silicone molding: liquid injection, gum injection, transfer molding and compression molding.  Our molding philosophy is to minimize secondary operations by developing the best mold and delivering the highest quality product possible.

Fabrication Process: Utilizing a custom-built mold, cold silicone LSR or HCR material is injected into the mold cavities and then heated to vulcanize/cure and “trap” the material into the features of the mold cavities in order to achieve the desired shape/configuration.

Product Characteristics: Ideal for products that have complex geometrical or three dimensional features.  Due to the stiction properties of silicone, however, extracting extremely small parts from molds can fracture or tear the parts, imposing a higher minimum size constraint on molded parts.  In addition, production volumes must be large enough to justify the investment in a custom-built mold.  Products can be sold as component parts or assembled into a finished product.

Clinical Applications: artificial heart assembly, cardiothoracic surgery, long-term implants, ocular devices, radiation therapy, urinary treatment.

Technical Specifications:

+ Product Dimensions Starting at 0.008” (203.2 μ)
+ Production Tolerance a low as +/- 0.0005” (+/- 12.7 μ)
+ LSR and HCR Capabilities: Liquid or gum stock silicone material, based on the desired product application.
+ Transfer/Compression Molding: Suitable for prototyping and small production volumes.
+ Micro Molding: Useful for smaller part sizes/dimensions.
+ Overmolding/Insert Molding: Molds silicone over, under or through a substrate material into an assembled product.
+ Mold and Tool Design: Generate Solidworks drawings for both prototype and production molds.
+ Multi-Axis Precision Machine Shop: In-house mold making capabilities.
+ Custom Formulations and/or Pigmentations: X-ray shielding, antimicrobial properties or radiopaque striping can be formulated into the silicone material and/or a variety of solid or translucent colors can be applied.

Extrusion

Bentec Medical has extensive extrusion capabilities ranging from single lumen tubing to co-extrusions and multi-lumen tubing with up to 22 lumens and more possible.  Our proprietary extrusion processed allow us the ability of easily holding tolerances of +/- 0.001” and in some instances +/- 0.0005”. Extruded profiles are limited only by your imagination, plus some laws of physics.  Additional equipment includes multiple-axis laser micrometers and in-line cut-to-length machinery.

Fabrication Process: Silicone HCR material is forced through a die that forms the material into the desired shape or configuration, then the material is vulcanized/cured into its finished form after exiting the die.

Product Characteristics: Ideal for products that can be produced in long, consistent configurations and then cut to desired cross-sectional lengths and assembled into a finished product, such as simple or complex tubing designs.

Clinical Applications: Continuous glucose monitoring, cardiothoracic surgery, ENT surgery, peristaltic pumps, radiation therapy, spinal surgery, surgical instruments, urinary treatment, wound drainage.

Technical Specifications:

+ Extrusion ID Size Starting at 0.001” (25.4 μ)
+ Wall Thickness Starting at 0.001” (25.4 μ)
+ Extrusion OD Size Starting at 0.003” (76.2 μ)
+ Extrusion ID/OD Tolerance as Low as +/- 0.0005” (+/- 12.7 μ)
+ Multi-Lumen Capabilities: > 20 lumens, as required by the product application.  Lumen shapes include round, elliptical, polygonal, crescent, etc.
+ Solid Rod and Complex Profile Extrusion: Non-tubular customized shapes.
+ Co-Extrusion: Two or more extruders produce separate strands of extruded silicone that are joined into a single extrusion and vulcanized/cured together as a single assembly.
+ Layering: A single strand of uncured extruded silicone is vulcanized/cured together with a pre-cured silicone extrusion or other material into a single assembly.
+ Wire Coated or Cable Sheathed Tubing: A single strand of uncured extruded silicone is wrapped with either wire coating or cable sheathing and vulcanized/cured together into a single assembly.
+ Balloon Extrusion: an extruded silicone tube that includes a thin-walled inflatable section that is used to fixate a device.
+ Custom Formulations and/or Pigmentations: X-ray shielding, antimicrobial properties or radiopaque striping can be formulated into the silicone material and/or a variety of solid or translucent colors can be applied.

Calendered Sheeting

Bentec Medical has some of the most extensive calendering experience in the industry with unparalleled quality and consistency.  Utilizing the silicone formulation of your choice, we have the ability of fabricating thicknesses ranging from 0.001” to 0.125” for non-reinforced sheeting and 0.006” to 0.150” for reinforced sheeting.  We can supply both vulcanized and unvulcanized silicone sheeting in both sheet stock or as a continuous roll.

Fabrication Process: Silicone HCR material is milled to an intermediate thickness and then fed through multiple heavy rollers in a calendering process that produces silicone sheeting in a final uniform thickness.

Product Characteristics: Ideal for products that can be fabricated using a flat silicone sheeting material.  Depending on the desired performance characteristics, silicone sheeting can be evenly layered with other materials such as a performance mesh reinforcement or other non-silicone substrate.  Calendered HCR material is “breathable” and facilitates O2 permeability.  Products can be sold as sheet or rolled stock, die cut/kiss cut into desired shapes or assembled into a finished product.

Clinical Applications: wound care, acute pediatric intestinal surgery, long-term implants.

Technical Specifications:

+ Thickness Starting at 0.0005” (12.7 μ)
+ Production Tolerance as Low as +/- 0.0005” (+/- 12.7 μ)
+ Vulcanized or Unvulcanized: Uniformly cured or uncured.
+ Hybrid Vulcanized/Unvulcanized: Sectionally cured/uncured.
+ Reinforced or Non-Reinforced: Standard silicone sheeting can be reinforced with a performance mesh material that increases surface strength and reduces flexibility, as required by the product application.
+ Custom Formulations and/or Pigmentations: X-ray shielding, antimicrobial properties or radiopaque striping can be formulated into the silicone material and/or a variety of solid or translucent colors can be applied.

Casting/Knife Coating

Fabrication Process: Silicone LSR, gel or dispersion material can either be manually skived out of a customized mold (casting) or spread into a consistent film using an automated blade (knife coating).

Product Characteristics: Ideal for products that can be fabricated using a flat silicone film material.  Depending on the desired performance characteristics, silicone film can be evenly layered with other materials such as a performance mesh reinforcement or other non-silicone substrate.  Given the breadth of raw materials, variables such as the “breathability” and durometer of the silicone material can be controlled more easily.  Products can be sold as film or rolled stock, die cut/kiss cut into desired shapes or assembled into a finished product.

Clinical Applications: blood storage, long-term implants, wound therapy.

Technical Specifications:

+ Thickness Starting at 0.0005” (12.7 μ).
+ Production Tolerance as Low as +/- 0.0005” (+/- 12.7 μ)
+ Vulcanized or Unvulcanized: uniformly cured or uncured.
+ Hybrid Vulcanized/Unvulcanized: sectionally cured/uncured.
+ Reinforced or Non-Reinforced: Standard silicone film can be reinforced with a performance mesh material that increases surface strength and reduces flexibility, as required by the product application.
+ Custom Formulations and/or Pigmentations: X-ray shielding, antimicrobial properties or radiopaque striping can be formulated into the silicone material and/or a variety of solid or translucent colors can be applied.

Secondary Fabrication Processes

Proprietary Surface Bond Treatments: used to improve the adhesion of coatings or other materials to the surface of silicone or to improve the lamination strength of a silicone assembly.

Dielectric Testing: Measures the durability of silicone insulating material in electronic devices, ensuring material fitness, as well as performance and safety standards.

Sub-Assembly: Two or more parts assembled together.

Final Assembly: Turnkey contract manufacturing of finished devices.

+ Laser Etching/ Engraving
+ Pad Printing
+ Inline Cutting
+ Die Cut/ Kiss Cut
+ Laser Cutting
+ Proprietary Surface Bond Treatments: used to improve the adhesion of coatings or other materials to the surface of silicone or to improve the lamination strength of a silicone assembly.

The Bentec Difference

Collaborative

• Product Design & Development
• Technical Assessment Consulting
• Material Science Expertise

Value Creating

• Project Proposal with Value Adds
• Mold/Tooling Design
• Validation Plan IQ/OQ/PQ

Lean Driven

• Design for Manufacturability
• Lean Process Deployment
• Advanced QC Techniques

Domain Expertise

• Molding, Extrusion, Sheeting
• Intricate Component Assembly
• Regulatory, Certification Support

Customer Centric

• Proactive Customer Service
• Ongoing Engineering Support
• Rigorous Quality/Delivery Compliance

The Bentec Advantage

Quality - Delivery - Cost

Building Trust, with 25+ Years of Serving Fortune 500 Medical OEMs

Bentec Medical Products

Interested in learning more about our custom design and manufacturing?