Medical Contract Manufacturing Dip Casting Capabilities

Medical Dip Casting

Dip casting might be the best manufacturing method for your silicone medical device, depending on your requirements. It is ideal for forming complex shapes, ultra-thin walls, and/or large envelopes/shells. The process requires special skill, and Lubrizol Life Science Health has perfected it. 

Achieving Precision Through Dip Casting

The silicone dip casting process begins with a custom-fabricated mandrel. Our experts dip the mandrel into a silicone dispersion to achieve the required wall thickness. The silicone is cured  before removing the component from the mandrel. The dipping technique, viscosity and temperature of the silicone, the manufacturing environment, and the curing time all factor into the quality of the finished silicone component.

Dip cast components are extremely precise because the silicone follows the geometry of the mandrel. For example, the process eliminates parting lines and allows for undercuts that would otherwise prove difficult, if not impossible to achieve through conventional molding methods. By carefully controlling the dipping protocol, we hold wall thicknesses to extremely tight tolerances.

An Economical Solution for Medical Device Prototyping

Tooling and setup costs for dip casting can be less than other manufacturing methods as you may avoid the need to invest in more costly steel based molds, making it a strong option for medical device prototyping — especially if your design requires multiple iterations.

An Optimal Method for Manufacturing Silicone Medical Balloons

Dip casting is the ideal method for manufacturing large, thin-walled silicone balloons. That’s because cured silicone dispersions allow for minimum vs. maximum diameters of 5:1 or more. Dip cast silicone balloons can be used to occlude or expand tissue, or to hold a device in position. Read our silicone balloon article to help you choose the right manufacturing method for your silicone balloon — dip casting, extrusion or molding.

From Design to Optimized Volume Medical Device Assembly

At LLS Health, we truly do care for the life of your product. We offer a complete range of manufacturing and support services — from design assistance and prototyping to dip casting and medical device assembly.

Expertise in Meeting Specifications 

  • Wall thickness as thin as 0.002" (0.05mm)
  • Wall tolerances as tight as ± 0.0005" (0.00127mm) depending on part geometry
  • Flash-free components without parting lines

Additional features

  • Surface options include Macro or Micro Textures, smooth, or optically clear
  • Prototype molding for rapid product development services
  • Laser marking

Contact a Local Expert

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Depend on LLS Health for your next molding or extrusion projects.