Case Study
Advantage Converting Enables Medical Device Manufacturer to Bring Tissue Expanding Balloon to Market
Challenge
A medical device manufacturer had a concept and prototypes for an implantable surgical device. Under doctor’s instructions, the device – an inflatable balloon – would allow a patient to self regulate the expansion of tissue in preparation for a complex surgical procedure. The manufacturer needed a partner to process flexible materials, assist with clinical trials, and scale production.
Solution
Advantage ConvertingConverting is the process of transforming raw materials—such as films, foils, papers, foams, fabrics, and adhesives—into finished or semi-finished products through specialized manufacturing processes. developed a method for manufacturing the medical balloon. This involved a thermal laminationBonding two or more webs (films/foil/paper) to create a single structure with combined barrier, strength, and seal properties. process and custom tooling that seals and die cuts the materials that comprise the balloon. We die cut a barrier film into a specified shape. This was island placed on a thermoplastic film and thermally bonded with another layer of thermoplastic film to create the balloon, which then went through a final die cut stage to cut the perimeter and produce the final part.
Results
- Advantage Converting successfully assisted the manufacturer in building a high quality functional device that went to trial
- Our deep partnership with materials providers enabled us to procure source materials the manufacturer couldn’t obtain on their own
- Seamlessly moved from prototype phase to full scale manufacturing
