LEARNING CENTER

Packaging is often the last thought in a medical device’s development process. Engineers focus on the actual design and functionality of the device itself before thinking about the packaging. Devices need to be protected from physical damage, biological contamination, and other external factors that sacrifice the integrity and sterility of the device.

Thermoforming and injection molding are two of the most common plastic manufacturing processes. Both processes offer different advantages depending on the specific application, part volume, and budget. Read more to learn about the two processes and which one would be best for your application.

Selecting the correct plastic material for medical device packaging is critical for ensuring a successful finished part. Each material has different characteristics, properties, and strengths that are ideal for different applications. Therefore, many factors can influence material selection ranging from performance to appearance to cost. By investigating project parameters and requirements, Brentwood’s team can help choose the best, most cost-effective material to meet packaging goals and regulations.

A customer came to Brentwood for updated packaging for their heart bypass machine kit. The original tray had numerous issues, which resulted in very high manufacturing and labor costs. The customer wanted a better packaging design that lowered costs. Our engineers got to work to solve the main design issues to meet the customer’s goal.

One of Brentwood’s customers came to us, looking for an alternative packaging solution for their bone marrow collection kit. The pouches they were using caused numerous challenges in surgical settings: the 15 pieces in the kit essentially had to be dumped out of the pouch, resulting in disorganization, and sometimes, enabling the components to fall off the tray.

The Brentwood Medical team is always looking to solve problems for our customers, even if it doesn’t involve creating an innovative packaging design. Our operations specialists are always looking for new ways to help our customers increase efficiencies at every stages of the supply chain.

Thermoforming is the primary manufacturing process Brentwood uses. Thermoforming is a timely and cost-effective solution for heavy equipment enclosures, diagnostic housing, packaging, in-transit shipping solutions, and more.

Brentwood Medical began manufacturing face shields in April 2020, in response to the personal protective equipment (PPE) shortages caused by COVID-19. As a custom packaging thermoformer serving the medical device, dental, and other healthcare industries, Brentwood had never designed or manufactured PPE, but this was a challenge they were excited to take on.

In 2017, Dentsply Sirona came to Brentwood in search of an improved packaging solution to their current off-the-shelf, injection molded polycarbonate boxes sourced from China. These boxes held their restorative dental products, including crowns, abutments, screws, and dentures. For the new packaging designs, Dentsply Sirona wanted easier to use packaging with a premium look that would reduce costs. The new trays and boxes would be part of a fully customized treatment box, tailored to each patient’s specific need