Selecting the right material is one of the most critical decisions in medical injection molding. The material determines the product's transparency, heat sterilization resistance, chemical compatibility, bio-compatibility, and overall cost. Whether you are developing disposable medical devices or high-performance surgical instruments, understanding the properties of different medical-grade plastics is essential.

This article introduces the most commonly used medical injection molding materials, explains their differences, discusses typical industry applications, and compares the relative costs of each material.

Why Material Selection is Crucial in Medical Injection Molding？

Medical device components must meet stringent sterilization requirements and maintain a dust-free production environment. Selecting appropriate materials not only ensures product performance but also helps manufacturers comply with standards such as ISO 13485, FDA, and USP VI when necessary.

When selecting materials, engineers typically evaluate: biocompatibility, mechanical strength, transparency, chemical resistance, sterilization compatibility, dimensional stability, and manufacturing cost.

Polypropylene (PP)  

Due to its excellent performance and cost-effectiveness, polypropylene has become the most widely used material in medical injection molding.  

Advantages: outstanding chemical resistance, lightweight, good fatigue resistance, compatible with ethylene oxide (EO) and gamma sterilization, suitable for high-volume production, and high cost-efficiency

Typical applications: syringes, sample containers, test tubes, pipette tips, medical device packaging, diagnostic consumables

Relatively low cost (approximately $1.5–2.5 per kilogram)

Polyethylene (PE)  

Polyethylene offers excellent flexibility and impact resistance while maintaining good biocompatibility.  

Advantages: high flexibility, durable, moisture-resistant, easy to process

Typical applications: medical bottles, tubing, packaging, liquid containers

Relatively low cost

Polycarbonate (PC)  

Polycarbonate is renowned for its excellent transparency and high impact resistance.

Advantages: Clear and transparent appearance, high mechanical strength, excellent dimensional stability, and superior heat resistance

Typical applications: oxygen masks, IV connectors, diagnostic device components, medical fluid containers, transparent housings

Relative cost: Moderate to high (approximately $4–8 per kilogram)

ABS

is typically used for medical device housings rather than components that come into direct contact with patients.  

Advantages: easy to mold, excellent surface finish, good dimensional stability, and high cost-effectiveness

Typical applications: medical device housings, diagnostic instrument enclosures, equipment cabinets, control panels  

Relative cost: moderate

Thermoplastic Elastomers (TPE)  

TPE combines the flexibility of rubber with the processing advantages of thermoplastic plastics.

Advantages: Soft surface texture, excellent grip, capable of overmolding, superior flexibility

Typical applications: medical handles, seals, flexible grips, soft-touch components, overmolded medical devices

Relative cost: Moderate

Liquid Silicone Rubber (LSR)  

Medical-grade LSR is gaining increasing popularity due to its flexibility, biocompatibility, and high-temperature resistance, and is widely used in products requiring these properties.

Advantages: excellent biocompatibility, outstanding flexibility, strong heat resistance, long service life, suitable for repeated sterilization

Typical applications: catheters, respiratory masks, valves, seals, infant medical products

Relatively high cost (approximately $10–20 per kilogram)

Polyetheretherketone (PEEK)  

PEEK is considered one of the highest-performance engineering plastics used in the medical industry.

Advantages: excellent mechanical strength, outstanding wear resistance, superior chemical resistance, high continuous operating temperature, suitable for implantable medical devices

Typical applications: orthopedic implants, spinal implants, dental implants, surgical instruments, high-performance medical device components

Relative cost is very high (approximately $60 to $150 per kilogram, or higher, depending on grade)

Polyphenylsulfone (PPSU)

PPSU is widely used in reusable medical devices that require repeated sterilization.

Advantages: excellent hydrolysis resistance, withstands repeated steam sterilization, high impact strength, long service life

Typical applications: surgical instrument handles, sterilization trays, dental equipment, reusable medical devices

Material Comparison  

Material	Strength	Transparency	Sterilization Tolerance	Typical Applications	Relative Cost
PP	Medium	Low	Good	Disposable consumables	Low
PE	Medium	Low	Good	Bottles, tubing	Low
PC	High	Excellent	Good	Transparent medical components	Medium–High
ABS	Medium	Low	Fair	Equipment housings	Medium
TPE	Flexible	Low	Good	Handles, seals	Medium
LSR	Flexible	Medium	Excellent	Catheters, masks	High
PPSU	High	Medium	Excellent	Reusable instruments	High
PEEK	Very high	Low	Excellent	Implants, surgical instruments	High

Which material is best suited for your medical project?  

No single material fits all applications.  

• PP and PE are preferred choices for disposable medical device components where cost-effectiveness is a top priority.  

• PC is ideal for transparent parts, especially when strength and dimensional stability are required.  

• ABS is suitable for medical device housings and structural components.  

• TPE and LSR are recommended for medical products requiring soft touch, flexibility, or injection molding.  

• PPSU is the best choice for reusable instruments requiring repeated steam sterilization.  

• PEEK is the preferred solution for high-performance implantable medical devices.  

When selecting the right material, consider product functionality, regulatory requirements, sterilization methods, production scale, and budget.

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