Foster, LLC listens to customers’ needs and develops products according to those needs. The product platforms we have developed below are available to customers as functionalized custom compounded products (ready to use) based on the needs of the specific application being developed.
The below platform product categories are available according to customer/application needs:
Imaging Visibility
Foster LoPro® Radiopaque Compounds include a wide range of the most advanced radiopaque fillers and medical contact grade polymers to create high-quality compounds required for small, ‘low-profile’ catheter designs. Medical device manufacturers can work with our team of polymer scientists to custom formulate a blend tailored to specific application requirements.
Radiopaque fillers include barium sulfate, bismuth subcarbonate, bismuth oxychloride, bismuth trioxide, and tungsten. These materials are used in interventional radiology, neurology, central venous catheters, guide wires as well as many other applications where fluoroscopy is the imaging technology of choice.
In addition to the standard LoPro® product line, Foster Corporation has also developed a portfolio of specialty radiopaque materials that were designed with the most critical application requirements in mind.
LoPro Clear™
Introduced in 2013, LoPro Clear™ is a radiopaque polyurethane that is both x-ray visible and optically transparent. Catheters extruded from LoPro Clear™ can be located inside the body using fluoroscopy, while fluid can be visually monitored outside of the body.
LoPro Plus™
LoPro Plus™ radiopaque compounds are reinforced with nanoparticles for improved pushability of thin-walled catheters. These compounds allow for extrusion of single layer catheters with radiopacity and strength equivalent to conventional bi-layer constructions, in which each layer provides a distinct property.
Foster has developed our own proprietary compounds for MRI and Ultrasound imaging technology. The need for non-radiation based imaging technology is the driving force behind the growth of these imaging techniques as public awareness has led to higher demand for less risky, and improved, diagnosis and treatment.
In addition, MRI’s have a superior diagnostic capability compared to other imaging techniques and ultrasound imaging offers “instant gratification” because its echo imaging that happens in real time.
Foster’s compounds for MRI and ultrasound imaging can also be used for permanently implantable applications.
Lubricity/Coefficient of Friction
Foster’s Propell™ low friction additive technology has become the industry standard when it comes to lowering the surface coefficient of friction on plastic medical devices.
Foster ProPell™ Low Friction Compounds is a platform technology for modifying the surface energy and frictional properties of medical polymers. This surface modification technology substantially reduces the inherent high friction and tackiness of lower durometer thermoplastic elastomer polymers commonly used in medical devices, allowing for improved manufacturing, handling, and most importantly, improved device functionality.
With PFA’s under scrutiny and regulatory actions being considered on materials that contain PFA’s, Propell™ is a viable alternative to many of the current PFA containing materials for lowering friction in medical polymers as Propell™ can be formulated PFA free.
Foster Corporation’s team evaluates each application and its requirements in order to custom-formulate Propell™ technology to meet specific performance demands. Material choice, translucency, color, and post-processing steps are all considered to ensure an optimal formulation for each unique project. Though the formulations are custom, all components have been tested and passed USP Chapter 88 Class VI Biological Reactivity studies.
Antimicrobial
Hospital-associated infections (HAIs) continue to be a critical problem in hospital environments, raising patients’ cost of healthcare, increasing their time in the hospital, and, at worst, causing death to affected patients.
In terms of medical catheters, the risk of infection is particularly high for those tubes and components that are left in place for three or more days (i.e., in-dwelling catheters). In this case, handling and exposure of these devices can influence time of onset and severity of infection. Infections often occur at incision points, where catheters enter the blood vessel and bacteria is introduced into blood- stream.
Foster Combat™ antimicrobial technology can be an effective weapon in the battle against HAIs. Foster’s antimicrobial technology features Sciessent Agion™ ionizing silver based antimicrobial additive that is compounded directly into the polymer so the antimicrobial effects help protect the plastic from bacterial growth and the patient from infection.
In addition to silver-based solutions, Foster has also developed antimicrobial technologies using a combination of silver and polymer-based solutions, along with copper and zinc- based antimicrobial additives. All formulations are custom developed to achieve specific application requirements.
Color
Colored polymer components provide functionality and aesthetics in medical applications. Colors are used to differentiate product type, size, or model. Certain colors may even convey meaning, such as reds or yellows for warning notification.
Colored polymer components can be produced from masterbatch concentrates (blended into natural polymer prior to molding or extruding) or pre-colored polymers via melt blending/compounding. The selection of one coloring method over the other may vary based on economics, secondary operations and end application.
Foster Corporation has processing capabilities to manufacture both masterbatch and pre-colored polymers. Our experienced color matching team, material scientists, and process engineers are available to select the most appropriate coloring technique for your requirements.
Pre-color or Masterbatch
Masterbatches or color concentrates provide an economical solution for long manufacturing runs of high-volume parts. Sufficient setup time is required to ensure the concentrate is properly blended prior to and during the melt processing phase in order to achieve the desired color consistency from part to part. This investment may be offset by the economies gained from using a high proportion of unmodified polymer at a reduced price.
The use of masterbatches however, can present several challenges. Metering undried masterbatches into hygroscopic resin may impart additional water, which may cause undesirable part appearance, processing, and or performance issues. Also, masterbatches require additional handling that may be inconsistent with the natural polymer to which it is added; subsequently resulting in potential production variability. Concentrate pellets are also denser than the natural polymer pellets and tend to sift downward in the hopper, often leading to variable loading levels and color drifts throughout a production run. Although the use of color metering weigh feeders can minimize variation, it also requires additional equipment and production controls. This in turn, reduces the potential cost savings for short production runs.
Pigment Selection
Pre-color compounds and masterbatches can be manufactured using FDA Food contact grade Pigments listed under FDA 21 CFR part 173-178 or using FDA Medical Device Pigments listed under FDA 21 CFR Parts 73 and 74. For medical applications, the selection of one pigment classification over the other may affect the FDA approval process.
LazerMed™, Brand Security, Reinforcement, Stabilization
LazerMed™ is a polymer additive technology that provides a high resolution, permanent and eco-friendly alternative to solvent based printing for medical device applications. LazerMed™ is manufactured using Merck EMD (Darmstadt, Germany) Iriotec™ “state-of-the-art” laser marking biotested (USP Class VI) pigments to provide a versatile printing platform that can be used in the vast majority of plastic materials.
Authentix® covert brand security taggants protect medical device brands by allowing the device brand owner to authenticate their device through the addition into a polymer of an inorganic “taggant” that is only detected via a proprietary electronic detection device…it is strong protection from unauthorized device copying. The biotested taggant material (USP Class VI) is added in small amounts into the polymer so it doesn’t affect the material’s physical properties and is easily identifiable via the detection device.
Foster’s compounding capability includes the addition of reinforcing additives into appropriate materials. These reinforcing materials add strength and, in the right polymer (such as nylons), heat resistance. Reinforcements include nano clays, glass, carbon fibers, and carbon nanotubes.
Stabilization includes processing, heat, UV, light, antioxidants as well as other technologies that help your compounds withstand the rigors of processing and harsh environmental elements so you can be assured that your medical device stays strong and performs at optimum expectations
Fostalink™ is a specialty thermoplastic post-processing crosslinking technology that improves physical properties and heat resistance. Can be advantageous in heat-shrink tubing.