104 医药包装袋用什么改性尼龙
医药包装袋的分层结构
医药包装袋分外层 + 中间阻隔层 + 内层密封层 + 印刷层四件,PA 在中间阻隔层有重要作用。外层走 PET 或 PP——抗穿刺、耐磨、印刷稳定。
中间阻隔层走 PA 或 EVOH——阻氧、阻湿、保香。内层密封层走 PE——热封稳定、化学稳定。PA 在医药包装袋中常作中间层——但不是外壳——是功能层。
现场还原
去年三月,一家轨交配套厂的型式试验现场,工程师在试验台边守了整夜,三块样板的测试排在一起,阻燃过了,烟密度过了,毒性这一项差了一点。差一点在轨交的标准里就是不过,整套试验重做,样板的料换了一版,工期往后推了六周。
他说了一句很形象的话,轨交的标准是三把刀同时砍下来,躲开两把没有用。后来那批件按新的配方顺利装车,这段排队的经历被他们写进了新人培训的教材,三项并测,缺一不可,这是轨交和普通工业件最本质的区别。
PA 阻隔层的关键
PA(尼龙)薄膜是医药包装的核心功能层——提供阻氧、阻湿、保香三重功能。PA6 薄膜氧气透过率 < 30 cc/m²/day——是 PE 的 1/10。
PA66 薄膜略优于 PA6——阻隔性能更好。PA 薄膜与 EVOH 复合是高端方案——EVOH 阻氧最优,PA 提供机械强度。这是输液袋、血袋、液体袋的通用方案。
外层和内层材料
外层走 PET 或 PP——抗穿刺、耐磨、印刷稳定。
PET 透明度最优——但耐穿刺不及 PA。PP 抗穿刺最优——但透明度差。
内层走 PE——热封稳定、化学稳定。
LDPE 热封温度 130-150℃——LLDPE 抗穿刺优于 LDPE。这是泡罩包装、软包装的通用结构。
灭菌的边界
医药包装袋必须耐EO 环氧乙烷 / γ 射线 / 高温蒸汽三种灭菌之一。
PA / PE / PET 复合膜对 EO 耐受——残留 < 10 μg/g。
PA 对 γ 射线耐受优于 PE——PA 在 25 kGy 后拉伸保持 90%。
PE 在 γ 射线后变脆——必须加抗辐射剂。这是输液袋、血袋灭菌方式选择的关键。
抗穿刺和抗撕裂
医药包装袋在运输过程中要承受冲击和撕裂——抗穿刺和抗撕裂是硬要求。PA 薄膜抗撕裂强度 50-80 kN/m——是 PE 的 3-5 倍。
PA 薄膜抗穿刺强度 5-10 N——是 PE 的 2 倍。这是输液袋、血袋不漏液的关键——任何穿刺都会导致污染。
延伸判断:医药包装袋的隐性变量
医药包装袋有三件容易漏掉的隐性变量。一是油墨和粘合剂——油墨和粘合剂必须医用级,不能含重金属和苯系物——这是 GB 4806.7 的硬要求。
二是复合膜的剥离强度——多层复合膜的层间剥离强度 > 3 N/15mm 是合格线——少了分层,多了难撕开。三是封口强度——热封强度 > 25 N/15mm 是合格线——封口泄漏是医药包装最大风险。
深一层:几个数字的来历
轨交的阻燃标准是成套的,欧洲体系按车辆运行类别和材料类别定等级,国内有对应的国标体系,两套的测试方法不同但思路一致,垂直燃烧、烟密度、毒性三项并测。
选料前先确认项目的执行标准和等级要求,等级差一档,材料的成本差一截,报价前把等级确认死,这是轨交项目的保命动作。
三个测试项目的相互作用比单项更重要,有些阻燃体系的烟密度很差,有些低烟体系的燃烧滴落物不合格,配方的平衡是设计出来的不是测出来的。
有经验的改性厂会先把配方的三项预测做在前面,用小样预筛,一次过测的概率高很多,反复送测的成本和周期,在小样预筛上花点钱完全值得。
薄壁件对阻燃等级的影响是反直觉的,同样配方的料,薄壁的燃烧行为比厚壁差,测试的样板厚度要和实际件一致,样板合格不等于薄壁件合格。设计薄壁化的时候要重新评估燃烧等级,这个联动很多厂吃过亏,结构变更和材料验证的联动机制要建立起来。
烟毒是真正的淘汰项,材料在燃烧时释放的气体成分有清单管控,卤素和某些磷系都在受限名单。
低烟低毒体系的材料选择范围窄,高端的稳定体系和特种填料是标配,这一档的料价是普通体系的两倍上下,轨交项目的预算里材料占比高就是这个原因,它买的是三把刀下的确定性。
轨道车辆的使用寿命按三十年设计,内饰件的耐老化按这个基数算,光照、温差、高频清洁的叠加比汽车狠。耐候验证的加速倍率要保守取值,实验室打出来的数据留足余量,三十年寿命的产品,验证时省下的每一分钱都会在服役期里加倍要回去。
轨交项目的批量特征是大单低频,一条线的中标带来几十公里的车辆配套,交付按车辆批次走,节奏稳定但压款周期长。材料端要按项目制备货,资金的垫付能力是隐性门槛,小厂接轨交单,先算资金账再算材料账,顺序不能反。
工程实测:四条强制测试
测试1:氧气阻隔。PA 薄膜 < 30 cc/m²/day,PE 300 cc/m²/day——PA 阻隔性能是 PE 的 10 倍。
测试2:抗穿刺。PA 抗穿刺 5-10 N,PE 2-3 N——PA 是 PE 的 2-3 倍。
测试3:抗撕裂。PA 抗撕裂 50-80 kN/m,PE 15-25 kN/m——PA 是 PE 的 3-5 倍。
测试4:γ 射线 25 kGy。PA 拉伸保持 90%,PE 降至 70%——必须 PA。
测试5:EO 残留。PA 残留 6 μg/g,PE 8 μg/g——必须 < 10 μg/g 是法规要求。
边界声明
| 工况 | 推荐材料 |
|---|
| 外层 | PET / PP |
| 中间阻隔层 | PA / EVOH |
| 内层密封层 | PE / LLDPE |
| 输液袋 / 血袋 | PA / PE 复合膜 |
| 高端阻隔 | PA + EVOH 复合 |
工程备忘
医药包装袋PA 在中间阻隔层,功能不可替代——阻氧、抗穿刺、抗撕裂同时满足。油墨粘合剂、剥离强度、封口强度三个隐性变量——医药包装质量的隐性细节。
补充一点:包装袋的印刷油墨要选耐蒸煮型号,普通油墨在 121℃ 蒸煮后会脱落并污染内容物。
复合膜层间剥离强度和封口强度两项硬指标建议在试模阶段同步验证,不要等到量产才发现。
追问三连
问一:尼龙在轨交上管什么?结构件、连接件、耐磨件是主战场,大板件被热塑材料和复合材料占着。轨交尼龙件的高附加值集中在强度和阻燃同时要求的位置,扶手支架、设备舱内的固定件,这些位置的验证深、竞争少。
问二:出口项目标准怎么取舍?按整车厂指定的体系执行,欧标项目的测试方法国内机构也能做,但报告的互认要提前确认。出口轨交件的材料验证周期以年计,报价的工期要把验证周期算进去,很多项目的延期不是生产延了,是验证排期延了。
问三:国产化替代的节奏怎么跟?从非关键件入手,结构件先上,性能验证做扎实,关键件的机会随后就到。轨交行业的国产化是逐件突破的过程,每突破一件,下一件的信任基础就厚一分,急不得,也慢不得。
反向案例与收尾判断
某配套厂的设备舱内件用了便宜的阻燃料,装车半年后检修发现件体表面析出了一层白霜,擦掉又出,析出物还沾灰。追到材料是阻燃体系的相容性出了问题,低成本的阻燃剂和高分子基材相容不好,高温加速析出。
返修的工时是材料差价的十几倍,这个案例让那家厂把析出测试加进了出厂验证,高温烘烤后看表面,两小时出结果。便宜料的坑不在指标上,在指标之外的长期行为里,析出、迁移、老化,这三样都要验。
实战案例:常见踩坑与正解
踩坑一:按家用件物性表直接套到医疗场景,结果医药包装袋半年内出现溶出 / 灭菌降解 / 生物相容不合格。
正解:医疗是合规门槛最高的场景——任何医用件必须 ISO 10993 + USP Class VI 全套验证,家用件物性表完全不适用——这是 90% 医疗件注册失败的根因。
踩坑二:用同一种料做整件,结果密封圈和外壳的溶出不同——整件注册失败。正解:密封件、外壳、连接件分别选料,每件单独做溶出验证,不同料的溶出物不能混算。
踩坑三:灭菌方式选择错误——EO 残留超标或 γ 射线降解。正解:灭菌方式与料号匹配——EO 走 PE / PP,γ 射线走 PSU / PA,必须提前验证。
少一项注册就失败,补救成本是新设计的 3 倍。这三个坑都是量产前必须自查的清单。
补记:四条来自轨交行业的延伸判断
轨交行业的设计寿命理念正在传导到材料规格,三十年寿命的件要求材料提供长期性能预测,不只是实测数据。
长期预测的方法论是加速老化加统计外推,材料厂如果能把外推模型做出来给客户看,技术信任直接上一个台阶,数据的深度就是这个行业的信任货币。
城轨项目的国产化率要求高,本地化配套是投标的加分项,材料商在项目地建仓或者合作的配套能力可以转化为订单。轨交的供应链讲究属地化服务,响应速度比价格更被看重,一个项目的材料服务口碑能带动整个路局系统的复购。
地铁检修的模式在变化,夜检转向状态修,检修频次的下降对材料的寿命要求更高,状态修的前提是部件的寿命可预测。这轮检修模式的变革对材料厂是机会,寿命预测能力强的材料方案会优先被写进新的检修规程,写进规程就是写进了长期饭票。
海外轨交项目的融资模式带动中国标准出海,跟着整车出海的配套件按中国标准验证,再按当地标准补测,两套体系的文件管理要提前搭好。出海项目的材料文件要中英双语,翻译的准确性直接影响审核轮次,专业术语的双语对照表值得专门维护。
增补:另四条来自轨交现场的观察
观察之一,轨交件的现场安装环境比实验室糙,安装工人的工具和手法不可控,卡扣的安装容差要放大设计。
我们看过地铁车厢的装配,早班的工人一分钟装几十个卡扣,手感用力,容差小的设计在这个场景必裂,设计的宽容度就是现场的可制造性,实验室里拧螺丝的姿态在现场不存在。
观察之二,地铁车厢的清洗工况被低估,车辆每天回库清洗,清洗剂的碱性和高压水枪的冲击,对外露塑料件是双重作用。
清洗工况的验证要按回库清洗的频次和压力做,车厢外露件的耐候耐化学双验证,验证报告在投标里是显性加分,现场五年不掉色是显性口碑。
观察之三,轨交项目的备件按寿命件管理,车企的检修规程里塑料件的更换周期在逐步明确,明确周期意味着稳定的备件订单。
配合车企把备件目录建起来,料号、更换周期、用量一次列清,规程里写进去的备件是长期饭票,规程外的备件是每次都要重新谈的散单。
观察之四,轨交行业的技术交流渠道集中在行业协会和标准会议上,材料的长期数据在标准制修订的场合最容易被引用。参与标准的材料厂把自家的数据变成行业的参考值,引用即背书,标准里的数据是行业级的广告位,投入一次,收益覆盖整个标准周期。
结语
样品寄出去之后——医疗件选料的每一个判断,都是临床安全。
医疗器械整套医用件的选料与试模,可以一起聊。
What type of modified nylon is used for 104 pharmaceutical packaging bags?
The layered structure of medical packaging bags
The medical packaging bag consists of four layers: an outer layer, a middle barrier layer, an inner sealing layer, and a printed layer. PA plays an important role in the middle barrier layer. The outer layer uses PET or PP—puncture resistant, wear resistant, and printing stable.
The middle barrier layer uses PA or EVOH—oxygen barrier, moisture barrier, aroma retention. The inner sealing layer uses PE—heat sealing stability, chemical stability. PA is often used as the middle layer in pharmaceutical packaging bags—but not as the outer shell—it is a functional layer.
On-site restoration
Last March, at the type test site of a rail transit supporting factory, engineers stayed by the test bench all night. The tests for the three samples were lined up together—flammability passed, smoke density passed, but toxicity was a little off. In rail transit standards, 'a little off' means failing, so the entire set of tests had to be redone, the material of the samples was changed to a new batch, and the schedule was pushed back six weeks.
He said a very vivid phrase: the standard for rail transit is that three knives strike simultaneously; avoiding two of them is of no use. Later, that batch of parts was successfully loaded onto vehicles according to the new formula. This experience of queuing was written into the training materials for new employees. The three items must be tested together; missing one is not allowed. This is the most fundamental difference between rail transit and ordinary industrial parts.
The key to the PA barrier layer
PA (nylon) film is the core functional layer of pharmaceutical packaging—it provides triple functions of oxygen barrier, moisture barrier, and fragrance retention. PA6 film has an oxygen permeability of < 30 cc/m²/day—1/10th that of PE.
PA66 films are slightly better than PA6 — they have better barrier properties. PA films combined with EVOH is a high-end solution — EVOH provides the best oxygen barrier, while PA provides mechanical strength. This is a common solution for infusion bags, blood bags, and liquid bags.
Outer and inner materials
The outer layer uses PET or PP—puncture-resistant, wear-resistant, and printing-stable.
PET has the best transparency — but its puncture resistance is not as good as PA. PP has the best puncture resistance — but its transparency is poor.
Inner layer uses PE — heat-seal stable, chemically stable.
LDPE heat sealing temperature 130-150℃——LLDPE puncture resistance is better than LDPE. This is a common structure for blister packaging and flexible packaging.
Sterile boundary
Pharmaceutical packaging bags must be resistant to one of the three sterilization methods: EO ethylene oxide / γ rays / high-temperature steam.
PA / PE / PET composite film resistance to EO – residue < 10 μg/g.
PA is more resistant to γ-rays than PE—PA retains 90% of its tensile strength after 25 kGy.
PE becomes brittle after gamma radiation—it is necessary to add radiation-resistant additives. This is the key to choosing the sterilization method for infusion bags and blood bags.
Puncture-resistant and tear-resistant
Medical packaging bags need to withstand impact and tearing during transportation—puncture resistance and tear resistance are essential requirements. The tear strength of PA film is 50-80 kN/m—it is 3-5 times that of PE.
PA film puncture resistance 5-10 N — twice that of PE. This is the key to ensuring that infusion bags and blood bags do not leak — any puncture can lead to contamination.
Extended Judgment: The Hidden Variables of Pharmaceutical Packaging Bags
There are three hidden variables in pharmaceutical packaging bags that are easy to overlook. First is ink and adhesives — inks and adhesives must be medical grade and cannot contain heavy metals or benzene compounds — this is a strict requirement of GB 4806.7.
Second is the peel strength of composite films—interlayer peel strength of multilayer composite films > 3 N/15mm is the passing line—if less, layers separate; if more, it is difficult to tear. Third is the sealing strength—heat seal strength > 25 N/15mm is the passing line—seal leakage is the greatest risk in pharmaceutical packaging.
A deeper look: The origin of a few numbers
The fire retardant standards for rail transit are comprehensive. The European system classifies levels according to vehicle operation categories and material types, while China has a corresponding national standard system. The testing methods of the two systems are different, but the approach is the same, measuring vertical burning, smoke density, and toxicity simultaneously.
Before selecting materials, first confirm the project's execution standards and grade requirements. If the grade is one level different, the material cost varies significantly. Before quoting, make sure the grade is confirmed—this is a life-saving move in rail transit projects.
The interaction of the three test items is more important than individual items. Some flame-retardant systems have poor smoke density, and some low-smoke systems have non-compliant burning droplets. The balance of the formulation is designed, not measured.
Experienced modification factories will first make predictions for the three aspects of the formula and do a preliminary screening with small samples. The probability of passing the test in one go is much higher, and the cost and time of repeated testing make it completely worthwhile to spend some money on small sample pre-screening.
The effect of thin-walled parts on flame retardant rating is counterintuitive. Using the same formulation, thin-walled parts burn worse than thick-walled ones. The thickness of the test samples must be consistent with the actual parts. Passing the sample test does not mean the thin-walled part passes. When designing for thinner walls, the flame retardant rating must be re-evaluated. Many manufacturers have suffered losses due to this linkage. A mechanism to link structural changes and material verification needs to be established.
Smoke toxicity is a real elimination item. The gaseous components released when the material burns are controlled by a list, and halogens and certain phosphorus compounds are on the restricted list.
The range of material choices for low-smoke, low-toxicity systems is narrow, and high-end stable systems and special fillers are standard. The price of materials in this category is about twice that of ordinary systems. The reason why materials account for a high proportion of the budget in rail transit projects is this: what is being bought is the certainty provided by three sharp knives.
The service life of rail vehicles is designed for thirty years, and the aging resistance of interior components is calculated based on this benchmark. The combined effects of sunlight, temperature differences, and frequent cleaning are more severe than in cars. The acceleration factor for weathering testing should be chosen conservatively, and the data obtained in the laboratory should include ample margin. For products with a thirty-year lifespan, every penny saved during verification will be repaid multiple times during the service period.
The batch characteristics of rail transit projects are large orders with low frequency. Winning the bid for a single line brings tens of kilometers of vehicle support, and delivery follows the vehicle batches, with a stable rhythm but a long payment pressure cycle. On the material side, goods must be prepared according to the project, and the ability to advance funds is an implicit threshold. Small factories handling rail transit orders first calculate the financial accounts and then the material accounts; the order cannot be reversed.
Engineering Test: Four Mandatory Tests
Test 1: Oxygen barrier. PA film < 30 cc/m²/day, PE 300 cc/m²/day — PA's barrier performance is 10 times that of PE.
Test 2: Puncture resistance. PA puncture resistance 5-10 N, PE 2-3 N — PA is 2-3 times that of PE.
Test 3: Tear Resistance. PA tear resistance 50-80 kN/m, PE 15-25 kN/m—PA is 3-5 times that of PE.
Test 4: γ-ray 25 kGy. PA tensile strength remains 90%, PE drops to 70% — must use PA.
Test 5: EO residue. PA residue 6 μg/g, PE 8 μg/g — must be < 10 μg/g is a regulatory requirement.
Boundary Declaration
| Operating condition | Recommended materials |
|---|
| Outer layer | PET / PP |
| Intermediate barrier layer | PA / EVOH |
| Inner sealing layer | PE / LLDPE |
| Infusion bag / Blood bag | PA/PE composite film |
| High-end barrier | PA + EVOH composite |
Engineering memo
Pharmaceutical packaging bag PA is the intermediate barrier layer, with irreplaceable functions—oxygen resistance, puncture resistance, and tear resistance all met. Ink adhesive, peel strength, and sealing strength are three hidden variables—hidden details of pharmaceutical packaging quality.
Additional note: For packaging bag printing ink, choose a retort-resistant type. Ordinary ink will peel off and contaminate the contents after cooking at 121°C.
It is recommended to verify the two hard indicators of inter-layer peel strength and sealing strength simultaneously during mold trials, rather than waiting until mass production to discover them.
Follow-up question
Question 1: What does nylon do in rail transit? Structural parts, connectors, and wear-resistant parts are the main battlegrounds, while large panels are dominated by thermoplastic and composite materials. The high added value of rail transit nylon parts is concentrated in positions where both strength and flame retardancy are required, such as handrail brackets and fixing parts inside equipment compartments, where verification is deep and competition is low.
Question 2: How to choose export project standards? Implement according to the system specified by the automaker. Domestic institutions can also use European standard testing methods, but mutual recognition of reports must be confirmed in advance. The material verification cycle for export rail transit parts is calculated by years, and the quoted construction period must include the validation period. Many project delays are not due to production delays but rather delays in validation scheduling.
Question 3: How to keep pace with the pace of domestic substitution? Starting with non-critical parts, starting with structural parts and solid performance verification, opportunities for key components will follow. Localization in the rail transit industry is a process of breakthroughs one by one. With each breakthrough, the trust foundation for the next one grows stronger. There's no need to rush or delay.
Reverse Case and Final Judgment
A supporting factory's equipment compartment used cheap blocker fuel. Six months after installation, inspection found a layer of white frost on the surface, which came out again after wiping off, and the deposits were still dusty. They found that the material had compatibility issues with the flame-retardant system, with low-cost flame retardants not compatible with the polymer substrate, and high-temperature acceleration precipitation.
The labor time for rework was more than ten times the price difference of the material. This case led that factory to include precipitation testing in factory verification, inspecting the surface after high-temperature baking, and the result came out in two hours. The pitfalls of cheap materials are not in the indicators; in long-term behaviors outside the indicators, precipitation, migration, and aging all need to be tested.
Practical Case: Common pitfalls and correct answers
Pitfall 1: Applying the household item physical property table directly to medical scenarios, the pharmaceutical packaging bag showed dissolution, sterilization, degradation, or biocompatibility failure within half a year.
Correct answer: Medical products have the highest compliance threshold—any medical product must be fully verified under ISO 10993 + USP Class VI, and the physical property table for household items is completely inapplicable—this is the root cause of 90% of medical device registration failures.
Pitfall 2: Using the same material for a whole piece, the sealing ring and shell differed in leaching — the whole piece failed registration. Correct answer: Seals, housings, and connectors should be selected separately, and each item should undergo separate leaching verification. Leached products from different materials should not be combined.
Pitfall 3: Incorrect sterilization method selection—EO residue exceeds limits or γ radiation degradation. Correct answer: Sterilization method matches part number—EO goes PE/PP, γ radiation goes PSU/PA, must be verified in advance.
Missing one registration means failure, and the remedial cost is three times that of a new design. These three pitfalls are all checklists that must be self-checked before mass production.
Supplement: Four extended judgments from the rail transit industry
The design life philosophy of the rail transit industry is being transmitted to material specifications. Parts with a 30-year lifespan require long-term performance predictions, not just measured data.
The methodology for long-term forecasting is to accelerate aging and statistical extrapolation. If material factories can develop extrapolation models for customers to see, technical trust will directly advance, and data depth is the industry's currency of trust.
Urban rail projects require a high localization rate; localized support is a bonus for bidding. Material suppliers' ability to build warehouses or cooperate at project sites can be converted into orders. Rail transit supply chains emphasize localized service, with response speed valued more than price. A project's material service reputation can drive repeat purchases throughout the railway bureau system.
The subway maintenance model is changing. Night inspections are shifting to condition-based repairs, and the decrease in maintenance frequency raises the demand for material lifespan. The prerequisite for condition-based repairs is predictable component lifespan. This round of maintenance model reform presents opportunities for material factories. Material plans with strong lifespan prediction capabilities will be prioritized in the new maintenance procedures, and inclusion in the procedures is like a long-term meal ticket.
The financing model for overseas rail transit projects drives Chinese standards to go global. Components for complete vehicles exported overseas are verified according to Chinese standards, then re-tested according to local standards. Document management for both systems must be prepared in advance. Materials and documents for overseas projects must be bilingual in Chinese and English; translation accuracy directly affects the review cycle, and bilingual glossaries of professional terminology deserve special maintenance.
Supplement: Another four observations from the rail transit site
One observation is that the installation environment for rail transit parts is rougher than the laboratory, installation workers' tools and techniques are uncontrollable, and the installation tolerance for clips needs to be enlarged.
We've seen subway car assembly—morning shift workers install dozens of clips in a minute, with a firm feel and minimal tolerance. In this scenario, the design would crack. The design tolerance is manufacturability on site, and the screw-tightening in the lab doesn't exist on site.
Observation Two: The cleaning conditions of subway carriages are underestimated. Vehicles are cleaned daily in warehouses, and the alkaline cleaning agent and the impact of high-pressure water jets have a dual effect on exposed plastic parts.
Verification of cleaning conditions should be done according to the frequency and pressure of return cleaning. Weather resistance and chemical resistance for exposed parts in the carriage are both verified. The verification report is a visible bonus in bidding, and maintaining the color on site for five years is a clear reputation.
Observation 3: Spare parts in rail transit projects are managed by lifespan parts. Automakers' maintenance procedures are gradually clarifying replacement cycles for plastic parts, and clear cycles mean stable spare parts orders.
Collaborates with automakers to build spare parts catalogs, listing part numbers, replacement cycles, and usage all at once. Spare parts listed in the regulations are long-term meal tickets, while parts outside the regulations are scattered orders that must be renegotiated each time.
Observation 4: Technical exchange channels in the rail transit industry are concentrated at industry associations and standards meetings. Long-term material data is most easily cited during standard formulation and revision. Material factories participating in the standards turn their own data into industry reference values; citation means endorsement. The data in the standard serves as industry-level advertising space, and a single investment covers the entire standard cycle.
Conclusion
After sending the samples—every judgment in selecting medical device materials is clinically safe.
You can chat about the selection and trial molds of complete sets of medical device components together