Healthcare Materials for Medical Devices: Balancing Sterilisation, Performance and Sustainability
Jeff Hobbins
Managing Director, Ultrapolymers Ireland
As a Managing Director for Ultrapolymers Ireland, Jeff Hobbins has over 20 years’ experience in polymer distribution and technical support. Since 2003, Jeff has supported Ireland’s medtech sector with material selection, compliance, production and supply chain security. He is also a big Munster Rugby supporter, but don’t hold that against him!
As Ireland's medical technology sector continues to evolve, manufacturers face increasing pressure to develop devices that are safe, reliable, sterilisation-compatible, and more sustainable, without compromising performance or regulatory compliance. Ahead of Medical Technology Ireland, Ultrapolymers in Ireland is working closely with healthcare manufacturers to address these challenges through advanced material selection and technical support. From insulin delivery systems and auto injectors to diagnostic equipment and patient monitoring devices, choosing the right healthcare plastic is becoming a critical factor in successful product development. Through our collaboration with NexPoint Materials (the new name for Sabic IP (available from Ultrapolymers in Ireland, UK and the Benelux regions)), we help Irish medical device manufacturers navigate evolving sterilisation requirements, sustainability objectives and material performance demands with greater confidence.
Why Sterilisation Matters in Medical Device Design
Sterilisation is a fundamental requirement for healthcare products because it removes or deactivates microorganisms that can contribute to healthcare associated infections. However, sterilisation should not be adopted as a processing step without considering its impact.
Different sterilisation methods can affect a plastic material's mechanical properties, appearance, chemical resistance, and long term performance. As a result, sterilisation compatibility should be considered during material selection rather than after a device has been designed.
The challenge for engineers is selecting materials that deliver the required performance while remaining compatible with current and future sterilisation requirements.
Understanding Today's Sterilisation Technologies
Several sterilisation methods are widely used within the healthcare sector, each offering different advantages.
Ethylene Oxide (EtO)
Ethylene oxide remains one of the most widely used solutions for temperature sensitive medical devices. One of its key advantages is the ability to sterilise products within their final packaging. However, the process requires careful management of residual gases and specialised packaging systems.
Radiation Sterilisation
Gamma radiation, electron beam (e beam) and X ray sterilisation are commonly used for disposable healthcare products. These technologies eliminate the need for chemical sterilants but can influence material colour and long-term performance.
Vaporised Hydrogen Peroxide (VHP)
VHP is attracting increased attention as an alternative sterilisation method. It avoids many of the handling challenges associated with EtO while remaining suitable for temperature sensitive devices.
Steam Autoclaving
For reusable medical devices, steam sterilisation remains a preferred solution. The process exposes materials to temperatures typically ranging from 121°C to 134°C, requiring excellent heat resistance and dimensional stability.
UV-C Sterilisation
Growing interest in UV-C technology reflects its effectiveness against a broad range of microorganisms. As healthcare equipment becomes increasingly reusable, understanding the impact of UV-C exposure on optical and mechanical properties is becoming more important.
How Material Performance Can Be Affected
One of the most common misconceptions in medical device design is treating sterilisation compatibility as a simple pass-or-fail requirement.
In reality, performance can depend on multiple factors including sterilisation dose, exposure conditions, processing history, component geometry, and end-use requirements.
For example, radiation sterilisation may cause colour changes in some materials, even when mechanical properties remain suitable for the application. In markets where product appearance influences user confidence and brand perception, these cosmetic changes can be significant.
To help address this challenge, NexPoint has developed colour compensation technologies for selected healthcare grades including LEXAN™ polycarbonate materials and XYLEX™ PC/polyester blends. These technologies are designed to maintain visual appearance while preserving the performance characteristics required for healthcare applications.
Healthcare Materials Designed for Demanding Applications from NexPoint.
NexPoint's healthcare portfolio includes materials engineered specifically for modern medical devices.
VALOX™ HX325HP
This unreinforced PBT grade has been developed for demanding healthcare applications including insulin pumps, glucose monitors, inhalers, auto injectors and insulin delivery pens.
Key benefits include:
- Excellent environmental stress crack resistance
- Strong chemical resistance
- Compatibility with EtO and radiation sterilisation
CYCOLAC™ Medical ABS Grades
CYCOLAC™ HMG healthcare grades combine toughness, aesthetics and processability. They are well suited to insulin delivery systems, fluid management equipment and other devices requiring reliable moulding performance and biocompatibility.
LEXAN™ Polycarbonate Solutions
LEXAN™ healthcare grades provide the rigidity, dimensional stability and toughness required for precision medical components such as glucose monitoring devices, imaging equipment and drug delivery systems.
XYLEX™ PC/Polyester Blends
XYLEX™ materials offer a valuable balance of transparency, chemical resistance and durability. These properties make them suitable for fluid delivery and monitoring applications where optical performance and long term reliability are equally important.
CYCOLOY™ HC1204HF
This PC/ABS blend combines impact performance, low temperature toughness and excellent mouldability. Compatibility with both EtO and radiation sterilisation makes it a versatile option for a wide range of healthcare applications.
Sustainability is Becoming a Healthcare Design Requirement
While performance and safety remain the primary priorities, sustainability is becoming increasingly important throughout the healthcare value chain.
NexPoint is supporting this transition through a portfolio of ISCC PLUS certified bio circular engineering thermoplastics manufactured using renewable raw materials derived from waste and residue streams, including used cooking oil and crude tall oil.
Importantly, these materials are designed as drop in solutions. Manufacturers can potentially reduce product carbon footprint while maintaining the same material performance characteristics and without major product redesign.
The portfolio includes:
- LEXAN™ RA grades containing up to 89% bio circular content
- LEXAN™ RW grades containing up to 72.6% bio circular content
- Bio circular PC blend solutions across CYCOLOY™, GELOY™ and XENOY™ families
This enables healthcare manufacturers to advance sustainability objectives without compromising device performance or quality.
From Design Concept to Production Support
Selecting the right healthcare plastic is only one part of successful medical device development. Through our dedicated healthcare team, Ultrapolymers supports manufacturers from initial material selection and design evaluation through to moulding, validation, regulatory considerations, and production scale up. By combining application expertise with access to a broad range of medical polymers, including the NexPoint healthcare portfolio, coupled with our simulation services (Moldex3D), we help customers assess sterilisation compatibility, performance requirements, sustainability objectives, and processing considerations early in the development cycle.
This collaborative approach reduces material selection risk, supports faster decision making, and helps ensure that healthcare devices are designed for both manufacturing efficiency and long term market success.
Looking Ahead
The future of healthcare materials will be shaped by more demanding sterilisation requirements, increasing regulatory expectations, evolving patient needs and growing sustainability targets.
Selecting the right material is no longer solely about mechanical performance. It requires balancing sterilisation compatibility, dimensional stability, chemical resistance, appearance, manufacturing efficiency and environmental considerations.
Through collaboration with NexPoint Materials and its dedicated healthcare team, Ultrapolymers helps device manufacturers navigate these challenges with confidence. By combining healthcare specific materials, technical expertise and application support, we help customers move from material selection to successful product development while preparing for the healthcare requirements of tomorrow.
If you would like to meet with us Medical Technology Ireland this year please email me (Jeff.hobbins@ultrapolymers.com) or complete this form https://bit.ly/ContactUltrapolymers
Frequently Asked Questions
What plastics are commonly used in medical devices?
Common healthcare materials include polycarbonate, PBT, ABS, PC/ABS blends and PC/polyester blends due to their balance of mechanical performance, processability and sterilisation compatibility.
Which plastics can withstand radiation sterilisation?
Several healthcare grades including selected LEXAN™, XYLEX™, VALOX™ and CYCOLOY™ materials are designed to support radiation sterilisation processes. Final validation should always be conducted within the actual application.
Why is sterilisation compatibility important during material selection?
Sterilisation can affect appearance, mechanical properties and long term product performance. Considering sterilisation requirements early helps minimise development risks and redesign costs.
What are bio circular plastics?
Bio circular plastics are manufactured using renewable feedstocks derived from waste and residue streams rather than fossil based raw materials, helping reduce environmental impact while maintaining performance characteristics.
Can sustainable materials be used in medical devices?
Yes. Modern bio circular healthcare materials are designed to deliver equivalent performance to conventional alternatives while supporting sustainability objectives.
