Company insight
Advancing coating solutions with precision
With a focus on both innovation and precision, Formacoat has set itself apart by working collaboratively with customers to address the challenges of modern medical device development.
t the heart of Formacoat’s success is its commitment to collaboration. The company works side-by-side with customers to improve device performance by listening closely to their needs. ‘The Formacoat Formula’ is built on the simple yet profound question: “What do you want and why?” This guiding principle ensures that every solution is tailored to not only meet the technical requirements of a device but also the expectations of the end user. The firm’s multidisciplinary team – comprising chemists, mechanical engineers, production engineers and an on-site quality team – provides customers with a comprehensive support system that is available from initial concept through to full-scale production.
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the specific needs of each device. One of the company’s standout innovations is its proprietary grafting technology. This revolutionary process involves chemically bonding a durable, lubricious layer directly onto the device substrate. The result is a coating that is not only tunable – allowing adjustments in thickness and lubricity – but also highly resistant to issues like cracking and de-lamination. This is especially beneficial for medical devices with extremely small internal diameters, where traditional hydrophilic coatings may not perform effectively. The grafting process also presents a cost advantage, offering high performance without the premium price tag often associated with similar solutions.
“We have the ability to be like a miniature factory for prototypes, pilots and even manufacturing parts.”
Jesse Manley, head of research and development
Comprehensive range of coating technologies Formacoat’s extensive range of coating technologies is designed to address a wide variety of challenges in the medical device industry. The company collaborates with more than 45 coating formulators who offer over 90 different coating chemistries. This vast selection includes hydrophilic and hydrophobic coatings that control moisture and friction, as well as surface- blocking, anti-fouling and anti-microbial coatings that help prevent contamination and infection. Additionally, specialised coatings such as heparin, collagen and PSA/adhesive provide targeted benefits for different applications. By offering both thermal cure and UV cure processes alongside advanced grafting technologies, Formacoat delivers flexible solutions that can be adapted to
Integrating 3D printing for rapid prototyping and production In today’s fast-paced medical device market, speed and agility are crucial. Recognising this need, Formacoat has integrated 3D printing technology into its coating processes. This technology enables the company to rapidly prototype, test and iterate designs, drastically reducing development times. The use of 3D printing also allows for the creation of complex geometries and unconventional shapes that might be challenging or impossible to achieve through traditional manufacturing methods. By using 3D printing, Formacoat is not only streamlining production but also enhancing the structural strength of devices while reducing material usage and overall weight. Jesse Manley, head of research and
Medical Device Developments /
www.medicaldevice-developments.com
development at Formacoat, explains that early experiments with 3D printing quickly evolved into a core aspect of the company’s operations. “We have the ability to be like a miniature factory for prototypes, pilots and eventually even manufacturing parts,” Manley says. This vertical integration means that Formacoat can be agile in responding to new challenges and market demands, ultimately getting innovative products to market faster than ever before.
Tailored solutions for evolving medical device needs Medical device performance requirements have become increasingly demanding over time. Whether it’s stents, catheters, guidewires, meshes or films, each device presents its own set of challenges. Formacoat’s collaborative approach ensures that solutions are not only customised but also scalable. By drawing on a deep bench of technical expertise and a wide array of coating technologies, the company can deliver solutions that work well the first time around and, if necessary, adapt quickly when initial options do not meet the desired outcomes. This adaptability saves customers valuable time and resources, as they do not need to start over with a new vendor if challenges arise. In addition to its technical capabilities, Formacoat provides valuable guidance on regulatory compliance. The company’s staff, seasoned in medical device development and regulatory standards, helps ensure that every coating solution meets stringent quality and safety requirements. This proactive approach minimises the risk of delays in product launch and supports a smoother transition from development to full-scale manufacturing. ●
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