SECTORS
MEDICAL DEVICES
Integrated Rapid Manufacturing Solutions for Medical Devices:
Your Comprehensive Partner from Concept to Full-Scale Production
Concept
Accelerating your medical device concept with precision prototyping, including vacuum casting for fast, cost-effective models. Transform your vision into a reliable prototype, ready for production.
Development
Advance your medical device with low-volume injection moulding, providing high-quality, cost-efficient production for small batches. Ensure seamless transition from prototype to early-stage manufacturing with reliable, scalable solutions.
Production
Move to full-scale production with expertise in moulding, welding, and assembly. Achieve consistent quality and precision, ensuring your medical device is manufactured to the highest standards, ready for market deployment.
Concept
Accelerating your medical device concept with precision prototyping, including vacuum casting for fast, cost-effective models. Transform your vision into a reliable prototype, ready for production.
Development
Advance your medical device with low-volume injection moulding, providing high-quality, cost-efficient production for small batches. Ensure seamless transition from prototype to early-stage manufacturing with reliable, scalable solutions.
Production
Move to full-scale production with expertise in moulding, welding, and assembly. Achieve consistent quality and precision, ensuring your medical device is manufactured to the highest standards, ready for market deployment.
WHAT WE DO
Injectors
We specialise in the precision development of injectors, from concept to production. With advanced prototyping, moulding, and assembly, we ensure each injector meets the highest standards of safety, quality, and compliance, delivering efficient and scalable solutions tailored to your needs.
Inhalers
We excel in the development of high-precision inhalers, offering end-to-end solutions from design to production. Operating advanced prototyping, moulding, and assembly, we ensure every inhaler meets stringent quality, safety, and regulatory standards, providing scalable and efficient manufacturing tailored to your specific needs.
Diagnostics
We offer comprehensive diagnostics development, ensuring precision, quality, and regulatory compliance from concept to production, with scalable and efficient manufacturing solutions tailored to meet your needs.
Devices
We specialise in the development of medical devices, delivering precision, quality, and regulatory compliance from concept through production. Our scalable and efficient manufacturing solutions are tailored to meet your specific needs.
Capabilities
TRUSTED BY GLOBAL BRANDs
CASE STUDIES
Protoype injection mould tools
Drug Delivery Development
Component Development Partner
CASE STUDIES
Protoype injection mould tools
Drug Delivery Development
Component Development Partner
Prototype Injection Mould Tools
Kindeva Drug Delivery requested FRP to develop new prototype injection mould tools and to optimise the moulding processes of achieving fully production-representative injection moulded components. Kindeva Drug Delivery have world-class lab talent to find creative solutions for taking your drug and developing a stable, viable formulation.
Solution
FRP worked closely with Kindeva to create a new prototype injection moulding tool within the given timeframes to allow for testing and developing of components and to enhance product development.
Result
FRP developed a new tool and processes which allowed Kindeva to test fully representative components much quicker whilst supporting better product development.
Kindeva Drug Delivery requested FRP to develop new prototype injection mould tools and to optimise the moulding processes to achieve fully production-representative injection moulded components for some of our ongoing complex device development programs. These new tools and processes enabled Kindeva Drug Delivery to test fully representative components quicker than normal and help accelerate our product development. FRP provided excellent service from start to finish. We look forward to working with FRP on future programs!
– Ed Jackson, Device Development Team Leader – Kindeva Drug Delivery
drug delivery device development
FRP helps Coalesce roduct Development to significantly de-risk & accelerate its Drug Delivery Development.
“Drug delivery devices are extraordinarily difficult to develop. They need to provide a consistent dose every time they are used and are manufactured in very high volumes in automated processes in cleanrooms, yet they need to be very inexpensive and simple to use to meet the needs of patients. A critical part of the process is establishing whether a new design can meet the technical and user requirements as early as possible in the development process. We have in house technologies for in silico modelling and physical prototyping with 3D printing and CNC techniques, but these do not produce “real” parts. This is where we rely on FRP.
Solution
Coalesce and FRP have established a close collaboration over many years. FRP is our go-to supplier for early-stage development tooling and moulded component supply including to support clinical trials. Even before our concepts are fully fleshed out, we involve FRP in the development process to ensure that our concepts can be manufactured.
FRP’s in-house team provides excellent Design For Manufacture (DFM) support at these critical early stages, in combination with validated tooling & in-house CT scanning. This saves us (and our clients!) tens of thousands of pounds in wasted time, effort, and tooling that would otherwise not be suitable for subsequent scale-up to mass production & assembly.
Starting with DFM studies and intelligently designed Moldex Reports, then progressing to proper steel tooling and Moulding Process Optimisation (MPO) & Validation, FRP has helped guide our team through Concept to Clinical Trial phase time and time again.
Result
As a result of FRP’s comprehensive approach, we have significantly de-risked the scale-up phase of the device development process, enabling our clients to accelerate the time it takes to bring their medicines to market. This is a considerable competitive advantage for both Coalesce and its clients.”
- Dave Ahern, CEO - Coalesce Product Development
Component Development Partner
MedTech start-up mOm has developed a revolutionary lightweight incubator that has the potential to help reduce the shocking number of neonatal deaths that happen every year. As a young company developing a potentially life-saving product, mOm required a component development partner that could provide expert support as well as high-quality, high-value parts.
Solution
FRP was engaged to support the development of the incubator, providing critical base components as well as expert consultancy on manufacturing the product at scale.
Result
FRP’s efforts have provided mOm with the injection-moulding expertise that was integral to the continued success of their acclaimed incubator.
We are delighted with the production quality injection moulded components provided by FRP. From class-leading Design For Manufacture (DFM) consultancy through to expert injection moulding advice (including sequential gating on the larger parts) FRP delivered in every department. On time, on quality and on budget – as a start-up MedTech business you can’t ask for any more than that!
– James Roberts, CEO – mOm
UPC CAMBRIDGE
For the last two decades, UPC have been consistently delivering market-leading technology products to some of the biggest names in pharmaceuticals. Known to many as the go-to problem solvers of product design. Resolving issues at all stages – from concept to industrialisation — when others have long given up. When medical technology experts UPC Cambridge were faced with an urgent requirement for high precision injection mouldings in some unusual grades of materials, they turned to FRP for help.
Solution
As medical technology experts, leading pharma rely on UPC for lightning-fast product development, trusting them to get results first time – every time. Specially heated steel rapid tooling and FRP’s in-depth process knowledge combined to produce low volumes (i.e. typically <5,000 sets) of 5 different components in a range of high temperature polymers, including:
- 30% mineral filled POM – Ultraform® from BASF Corporation
- 43% glass and mineral filled LCP – Vectra® from Celanese Corporation
- 50% glass filled PAA – Solvay IXEF® from Solvay Speciality Polymers
These materials require tool temperatures at 100°C or higher, requiring heating circuits and advanced handling not usually available from standard rapid tooling & moulding vendors.
Result
FRP delivered high precision injection mouldings using uncommon grades of materials quickly and to the high quality levels UPC’s project require
When it came to sourcing the critical parts for this medical device, we needed a responsive manufacturing partner capable of supplying parts & modifications very quickly and at the high quality levels our projects require. This is a really tough combination to achieve and FRP have consistently delivered on every level.
– UPC Founder and Principal Engineer Bill Treneman
CT SCANNING
A global pharmaceutical company recently needed a dozen plastic injection moulded components CT scanning to enable detailed analysis of the geometry.
Solution
FRP used their in-house CT Scanner in combination with a really clear and simple PDF reporting structure to deliver the required information in just a few days.
Result
Our customer was able to quickly and easily understand the PDF data sets as part of a wider project.
We use CT all the time and are experienced consumers of this service. FRP have taken things to another level of clarity and made it really easy for us to get the understanding we need quickly and without any fuss- really nice job!
– Confidential, Senior Director- Global Device Development.
Quality and Environmental Certifications
