Plastics Materials & Processing for Medical Devices

Dates: 14th October, 2019 - 17th October, 2019 (4 days)

Duration: 9.15 am to 5.00 pm each day for the 4 days

Location: 7 Centre Court, Blyry Business and Commercial Park, Athlone.

Accreditation: Plastic Materials and Processing

Full Fee: €1495 including course manual, lunch and refreshments.

Course code: 5N3034

Programme overview

This programme is designed for personnel who are new to or already work in medical device manufacturing and who wish to gain a comprehensive understanding of processing for medical device manufacturing. The programme covers materials, testing, processing technologies (including injection moulding, extrusion) and validation requirements and is relevant to Operation, Supply Chain or Quality personnel who are involved in the product building (processing & assembly) of medical device products.

This programme is also suitable for anyone who wishes to know more about plastics materials and how they are processed and tested. Validation is also covered on this programme and it is becoming much more important across general manufacturing and not just in the manufacture of medical devices.

No prior knowledge of the subject material is assumed.

Learning outcomes

Learners will gain

  • A comprehensive understanding of processing for medical device manufacturing
  • A good understanding of material, testing, processing technologies and validation requirements and is relevant to Operation, Supply Chain or Quality personnel who are involved in the product buildingof medical device products.

Who is the course for

This programme is designed for:

  • personnel who are new to or already work in medical device manufacturing and who wish to gain a comprehensive understanding of processing for medical device manufacturing.
  • personnel who work in operation, supply chain or quality personnel who are involved in the product building (processing & assembly) of medical device products.

Content

  • Introduction to Plastic Materials – focus on medical polymers.
  • Polymer Processing Techniques – Extrusion, Injection Moulding, Thermoforming and Blow Moulding.
  • Material and Product Testing Demonstration.
  • Medical Devices and Process Validation

 Day 1:

Introduction to Plastic Materials

  • Where plastics come from – Overview of different materials structure, properties and typical applications
  • Typical processing conditions and characteristics
  • Commonly used polymers – specifically medical polymers. FDA material requirements.

 Polymer Processing Techniques

  • Overview of the various techniques available for conversion of plastic raw material to medical products and devices.

Thermoforming

  • Thermoforming Theory – Classroom session
  • Practical Demonstration of Thermoforming

  Day 2:

Injection Moulding

  • Injection Moulding Theory – Classroom session
  • Practical demonstrations of Injection Moulding
  • Injection Moulding defects and troubleshooting –
  • Overview of part design and mould design for medical devices and common design faults
  • Defects caused by incorrect machine settings (Practical session)

Day 3:

Extruded Tubing

  • Extruded tubing – Classroom session
  • Practical demonstration of Extrusion and Blow Moulding

Material and Product Testing – Demonstrations.

  • Various material and product testing techniques – demonstrations including tensile, impact, fall dart, melting point, material flow properties, density and material identification techniques.
  • Materials used in principal processes, test techniques and common defects.

Day 4:

Medical Devices and Process Validation    

  • Regulations that govern the medical device/ healthcare sector – ISO 13485 , FDA requirements – Class I, II and III devices
  • GMP – The controlled environment and cleanroom classifications. GDP
  • Overview of validation principles – The Validation Flowchart and overview of use of Tools for product and process validation: FMEA, DOE, etc.
  • Installation Qualification (IQ), Operational Qualification (OQ), Worst Case Scenario, Operational Windows. Equipment IQ/OQ and Performance Qualification (PQ)
  • Process Qualification / Validation
  • Responsibilities within the validation project team.
  • Validation Documentation Stages and documents: SOP, MVP, IQ, OQ, PQ; Protocols and Reports.
  • Life Cycle approach to validation projects
  • Risk Assessment & Validation   

Safety Shoes – Required on this course

Find out how to achieve a Major Award in Injection Moulding (Level 5)

 This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications – see www.nfq.ie  and is a mandatory component of major awards

  • 5M3080 – Plastics Injection Moulding
  • 5M3067 – Plastic Extrusion Blow Moulding
  • 5M3074 – Plastics Extrusion. 

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