Medical/Pharma

Medical Injection Molding Engineered for Quality, Reliability and Scale.
Hoffer Plastics partners with medical device, product and equipment teams to move from concept to validated production with confidence. We specialize in non-surgical medical components and products for a variety of applications, including test kits, medical packaging, in-home monitoring devices, drug delivery, diagnostics, glucose monitors, wearables, respiratory care, dental equipment and more.

As a MedAccred™ certified manufacturer, our expertise combines Design for Manufacturability (DFM), precision tooling, scientific injection molding and in-line quality controls to deliver consistent, compliant parts and sub-assemblies. Our focus is on helping you mitigate risk, accelerate time-to-market and ensure patient safety through the highest standards of quality.

We mold medical-grade thermoplastics tailored to mechanical, chemical and regulatory needs, including PC, PP, PE, PA (Nylon), POM (Acetal), PBT, PPSU/PSU, PEI, TPE/TPU and high-performance options such as PEEK or LCP when appropriate. We align resin, colorant and additive packages to biocompatibility and sterilization modalities (e.g., EtO, gamma, e-beam, autoclave) defined by the program.

Hoffer Plastics engineers collaborate early in development to optimize part design, tooling and process windows for stability at scale. Every DFM review focuses on achieving dimensional accuracy, cosmetic performance and long-term manufacturability.

• Uniform walls & draft to mitigate warp, sink, and residual stress.
• Ribs/bosses/radii for strength without cosmetic defects.
• Gate & venting that protect A-surfaces and weld-line locations.
• Datum schemes & tolerance budgets anchored to CTF dimensions.
• Early Design of Experiment (DOE) to determine robust parameter windows before scale-up.

Micromolding is a specialized form of medical injection molding used to produce extremely small, high-precision plastic parts. At Hoffer Plastics, micro tooling, tightly controlled processing and advanced micro-metrology (optimal / micro-CMM / CT as scoped) ensure dimensional accuracy measured in microns. Our team applies scientific molding principles to maintain consistency, surface quality and structural integrity even in the most intricate features.

Typical applications include micro-fluidic features, valves, interfaces and compact housings where feature fidelity and surface quality are critical.

Hoffer Plastics combines precision molding with automated assembly and in-line testing to deliver fully validated, production-ready medical components. Our systems integrate joining, marking, inspection and packaging operations to ensure efficiency, traceability and consistent quality.

• Ultrasonic welding / heat staking for fluid-tight joints and insert installation.
• Mechanical/adhesive assembly with torque/pull verifications.
• Laser marking / pad print / labeling for identification and traceability.
• Functional & leak testing integrated in-line to raise first-pass yield.

Clean handling & protective packaging to preserve cosmetic class and sterility path.

Hoffer Plastics operates under an ISO 9001:2015-certified quality system and holds MedAccred™  accreditation for injection molding – recognition of our commitment to process control and continuous improvement. Our Quality Management System (QMS) is built to align with customer and regulatory requirements, ensuring traceability, repeatability and confidence from kickoff through production.

• Process documentation: Control plans, work instructions and sampling plans aligned to your QMS needs.
• Measurement & SPC: Cavity balance, capability indices on CTF dimensions and gauge R&R.
• Change control: ECO management, deviation handling and clear communication cadences.
• Traceability & records: Lot/serial tracking and record retention defined at kickoff.

Every program is backed by data, documentation and proactive communication so quality isn’t just measured, it’s proven.

Scalability starts with smart design and disciplined production planning. At Hoffer Plastics, every molding program is engineered to balance tooling investment, cycle time and risk management to deliver consistency from prototype to high-volume production.

• Right-sized tooling path: Rapid, bridge and production tooling options, from single to multi-cavity, matched to your volume and timeline goals.
• Cycle-time optimization: Hot-runner strategy, cooling design and automation that improve throughput without compromising quality.
• Risk-managed supply: Qualified materials, spare inserts and cores, and proactive maintenance and repair plans to maximize uptime and continuity.

That combination of process discipline and proactive supply planning helps to keep programs running smoothly with consistent high-quality supply.

Our medical injection molding expertise supports critical non-invasive critical medical applications where consistency, reliability and validated performance are essential.

• • Drug-delivery & dispensing: Closures, fitments, valves and fluid-path components.
  • Diagnostic & lab: Housings, micro-fluidic features and precision interfaces.
  • Devices & wearables: Enclosures, windows/lenses, strain-relief and overmolded features.
  • Procedure disposables: Clips, connectors, ergonomic grips and protective covers
  • Packaging components, metal to plastic conversions
  • Dental and animal health care

With a legacy of innovation dating back to 1953, Hoffer Plastics combines expertise, scale and precision to deliver superior medical molding at every stage of production. Our 365,000-square-foot manufacturing campus houses 112 injection molding presses, organized into Focused Factories that centralize medical expertise, strengthen customer collaboration and drive consistent quality from launch through high-volume production.

• DFM-first collaboration to de-risk geometry, materials, and tolerances.
• Precision tooling & scientific molding with documented, repeatable windows.
• Validation-ready processes (IQ/OQ/PQ or PPAP as scoped) and robust metrology.
• Automation & vision integrated to stabilize quality at volume.
• Traceability & clean handling aligned to program requirements.
• End-to-end support from prototype to high-volume, with assembly, testing and packaging.
• Transferred molding expertise

Every program is supported by cross-functional teams focused on family, integrity, service and trust – values that have defined Hoffer Plastics for more than 70 years.

Ready to launch or transfer a medical molding program?
Share your CAD files, target resin, critical dimensions and tolerances, expected annual volume (EAV), sterilization method and validation needs. We’ll return a practical plan – tooling strategy, process window, metrology, and documentation path – to reach stable production.