Films and Fabrics for Medical Devices in Diagnostic Imaging and Operating Room Applications

Films and fabrics play a critical role in medical device performance, particularly in diagnostic imaging and operating room environments. These materials must meet demanding requirements for cleanliness, durability, flexibility, imaging compatibility, and manufacturability.

Selecting the right film or fabric is only part of the design challenge. The method used to bond or assemble these materials directly impacts product reliability, infection control, and overall lifecycle performance.

Film Materials Used in Medical Device Applications

Polyurethane (PU) Films

• Flexible and elastic
• Transparent or translucent options
• Medical-grade breathable and non-breathable options

Benefits include excellent patient comfort, good fluid resistance, and compatibility with imaging environments.

Resin Transfer Molding (RTM)

RTM provides excellent dimensional accuracy, smooth surfaces on both sides of the part, scalable production volumes, and improved cost efficiency as programs mature, making it ideal for enclosures, frames, and robotic systems.

Polyethylene (PE) Films

• Lightweight and non-porous
• Chemical and moisture resistant
• Cost-effective for disposable products

PE films are ideal for single-use imaging covers, surgical barriers, and protective device components.

Polyvinyl Chloride (PVC) Films

• Highly transparent
• Durable and tear resistant
• RF-weldable

PVC films support strong sealed seams and are commonly used where clarity and fluid containment are required.

Fabric Materials Used in Imaging and OR Devices

Polyester (PET) Fabrics

• High tensile strength and dimensional stability
• Durable under repeated cleaning

Polyester fabrics are commonly used for patient positioning straps, reinforcement layers, and table accessory covers.

Nylon Fabrics

• • High abrasion resistance
  • Flexible and lightweight

  Nylon is frequently selected for surgical positioning slings, restraint systems, and soft supports

Non-Woven Medical Fabrics

• • • Lightweight and breathable options
    • Fluid-resistant multilayer constructions

    Non-woven fabrics are widely used in disposable drapes, imaging covers, and protective barriers.

Common Bonding and Assembly Methods

Sewing

• • • • High mechanical strength for load-bearing fabrics
      • Ideal for reusable textile products

      Sewing is commonly used for straps, reinforced accessories, and structural textile assemblies.

Heat Sealing

• • • • • Creates smooth, fluid-resistant seams
        • Compatible with thermoplastic films

        Heat sealing is widely used for imaging covers, OR barriers, and disposable products.

Ultrasonic Bonding (SonoBond)

• • • • • • Fast cycle times with no thread or adhesives
          • Maintains breathability in non-wovens

          Ultrasonic bonding is ideal for lightweight fabrics and disposable medical products.

Radio Frequency (RF) Welding

• Produces strong, consistent sealed seams
• Best suited for PVC and polar materials

RF welding is used in fluid-management components and protective covers requiring airtight seals

Choosing the Right Carbon Fiber Partner

Films and fabrics are foundational to many medical devices used in diagnostic imaging and operating room settings. By carefully aligning material selection with appropriate bonding methods, manufacturers can ensure reliable performance, effective infection control, and long-term durability in demanding clinical environments.