by Sara McCaslin, PhD Sara McCaslin, PhD No Comments

Extruded PTFE Components: Versatility and Reliability in Harsh Environments

Extruded PTFE components are critical to many high-performance systems for industries ranging from pharmaceuticals to oil & gas. They deliver chemical resistance, low friction, and thermal stability in ways few other materials can match. When produced as rods, tubes, and sheets, they become seals, bushings, insulators, and more. In harsh environments where metals corrode and plastics wear out, extruded PTFE proves to be both versatile and reliable.

The Extrusion Process and Its Advantages

In extrusion, a heated polymer is forced through a precision die to form a continuous cross-section with a uniform shape. Unlike molding, which forms discrete parts, extrusion results in long lengths that can be cut to form multiple discrete components later. The typical extruded forms are rods, tubes, sheets, and profiles. Extrusion offers key benefits, including consistency, scalability, and excellent cost-effectiveness, for high-volume production runs. 

The Extruded PTFE Process

Unlike most thermoplastics, PTFE cannot be melt-extruded because it does not flow when heated past its melting point. PTFE extrusion relies on a cold-forming technique that begins with a very fine PTFE powder that has been mixed with a volatile lubricant. This compound is compressed into a preform under high pressure, producing a billet with sufficient integrity for further processing. The billet is then forced through a die using a ram-type extruder, creating rods, tubes, or profiles with a continuous cross-section.

Once extrusion is complete, the lubricant must be carefully removed, often by heating in a controlled environment. The part then undergoes a sintering cycle where it is heated above 327°C in order to fuse PTFE particles into a dense, consistent structure. This step is critical because sintering enhances mechanical strength, dimensional stability, and the chemical inertness PTFE is known for. The final product can then be machined into precise components such as seals, bushings, or insulators, depending on the intended application.

Unique Material Properties of PTFE in Harsh Environments

PTFE is a thermoplastic polymer that readily lends itself to a specialized extrusion process. It is extremely thermally stable with a usage range from -200°C to +260°C. PTFE is also known for its outstanding chemical resistance in that it is inert to most corrosive chemicals and solvents. Another excellent feature of PTFE is its low friction and non-stick surface, along with its self-lubricating nature, all of which reduce wear in moving parts. In addition, PTFE has excellent dielectric properties. Finally, it is very dimensionally stable and exhibits resistance to creep and cold flow when appropriate fillers are utilized.

Extruded PTFE Components for Harsh Environments

Extruded PTFE components are ideal for harsh environments that may involve extreme temperatures, such as aerospace applications where there may be cryogenic and high-heat environments. They also work extremely well when aggressive chemicals are present, including oil & gas, chemical processing, and semiconductor industries. Extruded PTFE components exhibit excellent wear properties, making them an excellent choice for bearings, bushings, and seals designed for dynamic systems. Finally, they are a viable option for cleanroom and sterile environments such as those involving the medical, pharmaceutical, and food-grade compliance requirements.

Common Extruded PTFE Components and Use Cases

Rods are often machined into precision seals, bushings, and electrical insulators, where their ability to hold tight tolerances ensures consistent performance in demanding environments. Tubes find use as linings for process piping, sleeves for rotating shafts, spacers, and protective insulative covers, combining chemical resistance with electrical isolation. Sheets are commonly converted into gaskets, diaphragms, and wear pads.. 

Profiles and custom shapes make it possible to design specialized seals, connectors, or insulators tailored to unique dimensional and functional requirements. In practice, this includes PTFE bushings in cost-sensitive, high-volume assemblies where self-lubrication reduces maintenance, as well as extruded liners in corrosive fluid-handling systems that extend service life under aggressive operating conditions.

Enhancements Through Fillers and Modifications

There are some fillers that can significantly enhance the performance of PTFE. This includes glass-filled PTFE, which reduces creep and improves wear resistance. Carbon/graphite-filled PTFE is ideal for high-load and heat applications, while bronze-filled PTFE supports superior wear properties for use in bearing applications. There are PTFE blends that support improved electrical, mechanical, or chemical performance.

Conclusion

Extruded PTFE components do an excellent job of combining versatility, reliability, and adaptability across industries. And for engineers facing harsh environments, extruded PTFE provides a proven material solution that outperforms conventional options. We would like to encourage you to explore Advanced EMC’s range of PTFE rods, tubes, and sheets for your next application.

Medical application for polymer medical technology parts
by Sara McCaslin, PhD Sara McCaslin, PhD No Comments

Canted Coil Springs in the Medical Industry: Precision, Reliability, and Biocompatibility

Canted coil springs in the medical industry find a wide variety of applications, whether they are providing controlled force, stable electrical contact, or dependable sealing. Canted coil springs, also called slant coil springs, look deceptively simple. In reality, they are finely engineered components that offer something engineers in the medical field can’t do without: predictable performance in tiny spaces where failure is not an option.

In this blog post, we discuss the role of canted coil springs in medical devices, highlighting the features that make them stand out to engineers, their applications, and the design considerations involved in selecting the right type.

The Role of Canted Coil Springs in Medical the Medical Industry

Canted coil springs are angled, or canted, in such a way that they produce nearly constant force across a wide range of deflection. For medical devices, consistent force is often a necessity for reliability. Additionally, pacemakers, robotic surgical tools, and infusion pumps all rely on highly repeatable and dependable performance. The compact shape of these springs also makes them a good fit for miniaturized systems. This includes implantables, where every cubic millimeter counts. 

In fact, canted coil springs play a critical role across a wide range of medical technologies. In implantable devices (e.g., pacemakers, defibrillators, and cochlear implants), they ensure long-term, stable connectivity that patients can rely on. Surgical robotics benefit from connectors that incorporate canted coil springs to endure thousands of mating cycles without performance loss, making them easier to service and highly dependable in the operating room. In drug delivery systems such as infusion pumps or implantable reservoirs, spring-energized seals provide a consistent sealing force that enables precise, controlled dosing. Even advanced imaging equipment, including MRI and CT scanners, depends on these springs for EMI/RFI shielding and stable electrical interfaces, which preserve signal quality and reliability.

Why Engineers Rely on Canted Coil Springs in the Medical Industry

There are several key reasons why engineers rely on canted coil springs in medical applications.

Force Deflection Control

Canted coil springs are well known for their highly predictable load-deflection curves. In implantable devices, for example, stability over millions of cycles is essential. A spring that holds its force profile year after year helps reduce fatigue risks and mechanical drift, ensuring the device works as intended throughout its lifespan.

Sealing Performance

In spring-energized seals, canted coil springs are often paired with PTFE or other polymers. The result is a gas-tight, liquid-tight barrier that maintains its performance even in the presence of repeated sterilization cycles, aggressive fluids, and pressure changes. Engineers rely on this type of sealing solution for surgical instruments and drug delivery systems; leakage is simply not acceptable.

Electrical Conductivity

The angled coils on a canted coil spring allow it to be used as a highly reliable multi-contact electrical connectors. Instead of one or two contact points, they create multiple low-resistance electrical paths. These paths remain stable even under extremely harsh conditions that may involve vibration, thermal cycling, and repeated connections. This type of performance leads to lower insertion force, less wear, and added benefits like EMI and RFI shielding. For imaging systems, neuromodulation devices, and implantable electronics, these advantages lead to reliable signal integrity and longer service life.

Most Common Questions about Canted Coil Springs } Advanced EMC Technologies

Design Considerations for Engineers

Designing with canted coil springs can be complicated. Engineers need to tune load and deflection characteristics for the specific application, keeping stress within limits to extend fatigue life. This is made possible through the development of customized cant coil spring geometries.

As devices continue to shrink, tolerance control becomes critical. Finite element analysis is often used to predict performance under repeated load, while integration with polymers such as PTFE will enable hybrid solutions that balance mechanical, chemical, and biocompatibility needs.

Material choice is also vital, as it is where performance meets safety. Engineers typically work with stainless steel (316L), MP35N, Elgiloy, or Inconel due to factors such as corrosion resistance, fatigue life, and compliance with biocompatibility standards, including ISO 10993. For connectors, precious metal coatings like gold or platinum can further improve conductivity while resisting corrosion inside the body. Meeting these material and testing requirements is what makes it possible for springs to go from concept to regulatory approval.

Looking Ahead at Canted Coil Springs in the Medical Industry

As wearable and implantable medical electronics continue to grow, so does the demand for components that are smaller, lighter, and more efficient. Canted coil springs are well-positioned to meet that demand. Ongoing work with additive manufacturing and smart materials may add new features, such as adaptive force profiles or embedded sensors, that further expand their role in next-generation medical systems.

Conclusion

The ability of canted coil springs to maintain precise force, reinforce seals, and ensure electrical reliability makes them indispensable for a wide range of applications, from surgical robots to implantable devices. For engineers tasked with designing systems that must be both safe and dependable, these springs are a proven solution.

If you would like guidance on selecting or customizing canted coil springs for your next medical application, contact Advanced EMC. Our engineering team specializes in matching spring technology to the unique challenges of medical design. Give us a call today.