Healthcare-associated infections cost U.S. hospitals billions annually and put patients at risk. For OEMs designing medical equipment housings, material selection directly impacts infection control outcomes. The wrong choice means equipment that harbors bacteria, degrades under aggressive cleaning protocols, or fails to meet regulatory requirements.
Thermoformed housings offer OEMs a path to large-format antimicrobial components without the tooling costs of injection molding. But not all thermoplastic materials perform equally in clinical environments. Understanding the differences separates equipment that supports infection control from equipment that undermines it.
High-touch surfaces on medical equipment get cleaned dozens of times daily. MRI housings, patient bed components, diagnostic equipment covers, and mobile cart enclosures all face constant contact from staff, patients, and cleaning crews. Traditional plastics can develop micro-scratches that trap bacteria, creating reservoirs that survive even thorough disinfection.
Antimicrobial thermoplastics address this problem at the material level. Rather than relying solely on surface cleaning, these materials actively inhibit bacterial and fungal growth between cleanings. The distinction matters for equipment that operates continuously in high-acuity environments where infection risk is elevated.
Not every material marketed as antimicrobial delivers the same protection. Some rely on surface coatings that wear away with repeated cleaning. Others use additives that can leach out over time, reducing effectiveness as the equipment ages.
The most reliable antimicrobial thermoplastics incorporate protection throughout the material matrix, not just on the surface. KYDEX ION Technology, for example, embeds antimicrobial agents that remain effective for the life of the part. Testing shows 99% effectiveness against common bacteria, with protection extending below the surface where scratches and abrasions occur.
Plasticizer-free formulations offer another advantage. Many conventional plastics contain plasticizers that can serve as nutrient sources for microorganisms. Eliminating these additives removes a potential food source and reduces colonization risk from the start.
Hospital cleaning protocols have intensified over the past several years. Equipment surfaces now routinely encounter quaternary ammonium compounds, sodium hypochlorite solutions, hydrogen peroxide cleaners, and alcohol-based sanitizers. Many of these agents are aggressive enough to damage conventional plastics.
Material selection must account for this chemical exposure. A housing that looks great at installation but shows stress cracking, discoloration, or surface degradation after six months of cleaning fails your customer and damages your reputation.
KYDEX thermoplastics have been tested against CDC-recognized disinfectants including Super Sani-Cloth, CaviWipes, Clorox Disinfecting Spray, and Dispatch Hospital Cleaner with Bleach. After 28 days of continuous contact testing, materials maintained over 90% of their mechanical properties with no adverse surface effects.
Material selection depends on your specific application requirements. For general medical device housings requiring flame retardancy and good formability, KYDEX T meets UL94 V-0 and 5V standards while offering excellent deep-draw characteristics.
Applications requiring enhanced chemical resistance benefit from KYDEX 430, which handles the most aggressive cleaning agents without degradation. This grade also passes ball pressure testing per IEC 60695-10-2, making it suitable for components near heat sources.
When impact resistance is critical, KYDEX 110 provides superior protection for mobile equipment and portable devices that face handling stress. For housings requiring biocompatibility certification, grades meeting ISO 10993 standards are available.
PC/ABS blends like Allen 8300FR offer another option when non-halogenated flame retardancy is required alongside high impact strength and heat resistance.
Start with your end-use environment. What cleaning agents will the equipment encounter? What flame retardancy standards apply? Does the application require biocompatibility testing?
Request chemical resistance data specific to the disinfectants your customers use. Generic chemical resistance charts tell only part of the story. You need testing against the actual cleaning products found in clinical settings.
Consider the thermoforming process itself. Some antimicrobial materials require specific processing parameters to maintain their protective properties. Work with a thermoformer experienced in medical applications who understands these requirements.
Finally, verify that antimicrobial claims are backed by standardized testing. ASTM G21 and G22 provide established methods for evaluating resistance to fungal and bacterial growth. EPA registration confirms that antimicrobial claims meet regulatory standards.
The right material selection protects patients, supports infection control protocols, and ensures your equipment maintains its appearance and performance throughout its service life. PCI works with OEMs to match material properties with application requirements, from initial design through production.
Contact our engineering team to discuss your medical housing project and request material samples for evaluation.