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Everything You Need to Know About Compression Molded Foam for Medical Packaging

Combining high quality with low costs.

See why so many teams trust Janco for their compression molding projects.

Compression molding for the medical industry comes with a unique set of standards, from the biocompatibility of the foam being used to how your packaging is manufactured. Above all else, we pride ourselves on offering reliable solutions for your varying needs, creating packaging that will add value to your end product.

Our facilities include six ISO-certified cleanrooms, and our team offers guidance for best practices when it comes to our wide range of customizable manufacturing capabilities.

Do you have burning questions about medical grade foam and our compression molding process? Here’s what we’re getting into:

What is Medical Grade Foam?

The truth is, not every contract manufacturer will give you the same answer when you ask how they define medical grade foam. There are generally a few different types of foam used when manufacturing medical packaging through the compression molding process – closed-cell polyethylene and open-cell polyurethane foams.

At Janco, one main component remains most essential to declaring a foam ‘medical grade’: biocompatibility. If the foam has been cleared for medical packaging uses, it means that it has been tested, passed, and certified to comply with the ISO 10993 protocol.

This certifies that the foam will not produce a toxic or immunological response when exposed to the body or bodily fluids, which is a high priority when packaging is being used for medical devices or surgical trays.

Our manufacturing process for medical grade foams combines state-of-the-art equipment with high-quality biocompatible materials needed to withstand repeated multiple forms of sterilization methods.

Types of Medical Grade Foam

When it comes to compression molding, our team works with the closed-cell polyolefin family of foams, which includes cross-linked polyethylenes and ethyl vinyl acetate (EVA) foams. This can also include open-cell polyurethane foams.

Unlike most other contract manufacturers, our team can blend foams with a wide range of plastics if required. Through our lamination processes, our team is able to mold open and closed-cell foam composites.

Compression Molding Process

Our expert engineers can bring your packaging solutions to life using your exact specifications, but we also offer design assistance to enhance your product. Plus, as a distributor of foam and plastic from the world’s leading manufacturers, you get access to the best materials available.

Janco has the capabilities to mold large, intricate parts with low-cost tooling and minimal waste, so you get high-quality products without high costs.

Here’s how the process works once the design is finalized:

  • Your foam or foam composite is heated using an industrial convection oven and then placed in a machined, matched tool that we mount in a molding press.
  • The mold is closed using hydraulic pressure which applies enough force to push the pliable, heated material into contact with all of the mold surfaces.
  • Once the material has cooled, the mold is opened and the finished packaging is removed from the tool.
  • In most cases, our team can cut the perimeter and any internal features of the packaging through the molding process.
  • Cutting features during the molding process allows us to cut the expense of a secondary cutting operation.

Given the unique regulations often associated with medical industry manufacturing, we offer compression molding capabilities in our ISO-certified cleanrooms.

Compression Molded Packaging Products

Compression molding is the manufacturing capability of choice for a diverse range of packaging needs, spanning across several industries and uses. Our team has decades of experience creating unique packaging solutions both in the medical industry and beyond.

Here’s a quick breakdown of some common packaging products manufactured using the compression molding process:

Medical Uses

  • Medical packaging
  • Orthopedic implants
  • Medical instruments
  • Medical kits

Other Industry Uses

  • Custom packaging
  • Athletic equipment
  • Insoles
  • Helmet liners
  • Snow brooms

If you’re looking for packaging solutions for a product that isn’t listed here, don’t hesitate to reach out. Our job is to find a solution!

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Die Cutting VS Compression Molding

Because of the significant amount of overlap between the two services, we’re often asked to make recommendations between our die cutting and compression molding services.

Our team is what’s known in manufacturing as a ‘converter’ – we receive foams in a roll or bun form, and either die cut or compression mold it to manufacture whatever form of packaging is required for your project.

While die cutting allows for slightly more design input, compression molding still offers a high level of customization and is ideal for different types of products.

Compression Molded Foam Benefits

The compression molding process offers several benefits when compared to other manufacturing methods. The truth is, the benefits all come down to your exact needs. Manufacturing is all about innovation and precision, finding the right ways to add value to your product while helping you keep costs low.

A few common reasons why you would settle on compression molding include:

  • Customization – Every job that we do at Janco is custom, but the compression molding process offers a unique level of customization through the design phase of the project.
  • Protection – Compression-molded foam packaging can provide an ideal level of protection, particularly when trays have sharp edges that may damage other material. Being a soft packaging solution, foam is ideal to protect against tears or abrasions, particularly for kits with trays.
  • Simple Process – The process is quite simple for us, which means you’ll look forward to a relatively quick turnover time once the design and materials are settled on.
  • Cost-Effective – The compression molding process is especially cost-effective for short production runs, making it an ideal process for prototypes or samples that are being packaged.

Why Janco?

Beyond our innovative technology and state-of-the-art cleanrooms, what sets Janco apart is our determination to make the process as smooth as possible for you.

From design consulting to material selection, we work with you every step of the way to customize your packaging with added value in mind. For about six decades, Janco has been the go-to team for customizable compression molding services.

Reach out to us!

Learn more about our medical grade foam selection or how we can bring your packaging solution to life with the precision you need and at a price you’ll love.

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