Medical adhesive coating plays an important role in the production of pressure-sensitive adhesive materials used across healthcare and medical device applications. From wearable devices and wound care products to diagnostics and other skin-contact applications, the coating process must align with the materials, performance requirements, and intended use of the finished product.
Experienced adhesive coaters work with a range of adhesive materials, substrates, release liners, and coating methods to produce adhesive tape constructions aligned with application-specific requirements. When standard materials do not meet those requirements, custom adhesive coating can provide additional options for manufacturers evaluating materials for specialized medical applications.
At DermaMed, coating capabilities support pressure-sensitive adhesive materials used across a variety of medical and healthcare applications. Understanding the available coating processes and the factors that influence material selection can help manufacturers make informed decisions during material evaluation.
What Is Medical Adhesive Coating?
Medical adhesive coating is the process of applying pressure-sensitive adhesive materials to films, foams, fabrics, release liners, and other specialty substrates used in medical adhesive tape constructions.
The appropriate coating process depends on several factors, including the adhesive material, substrate, intended application, coating pattern, and performance requirements.
For medical device manufacturers, the adhesive is only one component of the overall construction. Wear duration, flexibility, breathability, moisture management, device compatibility, and manufacturing requirements can all influence the materials and coating method selected for an application.
This is why experienced adhesive coaters evaluate more than the adhesive itself when supporting medical applications.
Application Requirements Influence the Coating Process
There is no single coating process appropriate for every medical adhesive application.
A wearable medical device intended for extended wear may have different material requirements than a wound care product, diagnostic device, or surgical application. The intended use can influence the adhesive material, substrate, coating pattern, and other components of the construction.
DermaMed assists customers with identifying material constructions aligned with requirements such as adhesion, wear time, flexibility, moisture management, and device compatibility.
Evaluating these requirements early helps manufacturers identify coating and material options appropriate for further testing.
Understanding Different Adhesive Coating Methods
Different coating methods can support different adhesive constructions and application requirements. DermaMed’s coating capabilities include pattern and gravure coating, zone coating, knife-over-roll coating, and other processes used with pressure-sensitive adhesive materials.
Pattern and Gravure Coating
Pattern coating allows adhesive to be applied in specific patterns rather than uniformly across an entire material surface.
Depending on the construction, pattern-coated adhesives may be evaluated for applications requiring specific adhesive coverage or breathability characteristics. Gravure coating provides another method for applying adhesive materials across a substrate.
These processes give manufacturers additional options when evaluating adhesive constructions for application-specific requirements.
Zone Coating
Zone coating places adhesive in designated areas of a material while leaving other areas uncoated.
This type of construction may be useful when an application requires adhesive placement in specific locations rather than across the complete substrate. DermaMed identifies zone-coated adhesives among the material and product types it supports.
Knife-Over-Roll Coating
Knife-over-roll is another coating method available for pressure-sensitive adhesive materials.
DermaMed’s manufacturing capabilities include knife-over-roll coating at widths up to 60 inches. This capability supports adhesive coating across a range of materials and application requirements.
Materials Are an Important Part of Custom Adhesive Coating
The coating method cannot be evaluated independently from the materials used in the adhesive construction.
Depending on the medical application, pressure-sensitive adhesives may be combined with breathable films, foams, woven or non-woven materials, transfer adhesives, specialty films, and release liners.
For example, breathable materials may be considered when moisture management is an important application requirement. Foams may be evaluated where cushioning, conformability, or specific thickness requirements are involved. Woven and non-woven materials provide additional options where flexibility, breathability, durability, and skin compatibility need to be considered.
With custom adhesive coating, these material considerations can be evaluated together rather than treating the adhesive and substrate as separate decisions.
Testing Supports the Material Evaluation Process
Testing is another important part of evaluating a medical adhesive construction.
DermaMed’s on-site capabilities support adhesive evaluation through testing that can include adhesion to steel and HDPE, release, tack, shear, loop, Polyken Probe, MVTR testing, and accelerated aging.
Testing provides manufacturers with information they can use when comparing materials and adhesive constructions against application-specific requirements.
The evaluation process may also involve samples and modifications before moving toward larger production volumes. This allows manufacturers to evaluate material and adhesive construction options before moving into production.
From Material Evaluation to Production
A medical adhesive construction may move through several stages before production.
Initial discussions can begin with the intended application and its physical and adhesive requirements. From there, materials and coating options can be identified, samples evaluated, and testing performed.
DermaMed’s engineering support and material selection capabilities assist customers with identifying adhesive materials, specialty substrates, release liners, and material constructions aligned with application-specific requirements.
Once an appropriate construction has been identified, coating consistency and other manufacturing considerations become increasingly important as production volumes increase.
This progression allows manufacturers to evaluate both the adhesive construction and manufacturing requirements before moving into larger-scale production.
What to Consider When Evaluating Adhesive Coaters
Medical device manufacturers evaluating adhesive coaters should consider more than coating equipment alone.
The ability to work with different pressure-sensitive adhesives and specialty substrates, support multiple coating methods, provide material evaluation and testing, and assist with application-specific requirements can all be important considerations.
DermaMed supports manufacturers through adhesive coating, material selection, sample preparation, laminating, slitting, and testing capabilities. Its coating capabilities include multiple processes that can support different adhesive constructions and medical application requirements.
For manufacturers requiring something beyond an existing standard construction, custom adhesive coating provides an opportunity to evaluate materials and coating methods around the requirements of the specific application.
For broader information regarding medical devices and regulatory considerations, manufacturers can also reference the FDA Medical Devices resources.
Supporting Medical Adhesive Applications
Medical adhesive coating involves the interaction of adhesive materials, substrates, coating processes, testing, and application-specific requirements.
Understanding those variables can help medical device manufacturers evaluate potential adhesive constructions for wearable devices, wound care, diagnostics, and other skin-contact applications.
DermaMed supports this process through coating capabilities, material selection, laminating, slitting, testing, and engineering support. By considering the complete material construction rather than the adhesive alone, manufacturers can evaluate options aligned with their specific application and manufacturing requirements.
Need Support with a Medical Adhesive Coating Application?
If your medical application requires a standard or custom adhesive construction, DermaMed can assist your team with identifying materials and coating options aligned with your application-specific requirements.
F.A.Q.’s
What is custom adhesive coating?
Custom adhesive coating involves applying pressure-sensitive adhesive materials to selected substrates based on application-specific material and performance requirements.
What should manufacturers consider when selecting adhesive coaters?
Manufacturers may consider coating capabilities, available materials, testing resources, application requirements, and the ability to support material evaluation when selecting adhesive coaters.
What types of medical applications use adhesive coatings?
Adhesive-coated materials are used across wearable medical devices, wound care, diagnostics, surgical applications, and other medical products requiring pressure-sensitive adhesive materials.
What coating processes can be used for medical adhesive materials?
Coating processes can include pattern and gravure coating, zone coating, and knife-over-roll coating. The appropriate process depends on the materials and requirements of the application.
Does DermaMed provide custom adhesive coating?
Yes. DermaMed provides custom adhesive coating capabilities and supports customers with material selection, sample preparation, laminating, slitting, and testing aligned with application-specific requirements.