Why adhesives matter in medical device design

Excellence in medical devices serves one purpose: Above all, patient care and comfort. At the design stage, every detail matters.

When it comes to medical-grade adhesives, choosing the right material enhances your device’s performance across its entire lifecycle, from assembly to final use. Far from being just a finishing touch, pressure-sensitive adhesives are critical to product performance, patient safety and even production efficiency.

At iD Products, we help medical device manufacturers bring their project to completion with our custom-adhesive solutions. Whether you need a precision die cut adhesive-backed gasket that integrates seamlessly into automated workflows, a durable label that wraps securely around a small collection tube or a bond that withstands repeated cycles of sterilization — we’ve got you covered.

Mandrel labeling: Smooth, readable, reliable

Labeling mandrel surfaces — such as syringes, test tubes, or vials — is uniquely challenging. These cylindrical and often low-surface-energy containers require specialized adhesives paired with the right facestock that keep labels in place and its barcodes scannable.

Key requirements for mandrel labeling solutions:

• Flexibility: Both the adhesive and facestock must be highly flexible to conform to tight curves without peeling, wrinkling or forming air pockets.
• Reliability: Some mandrel containers are made from low-surface-energy plastics like polypropylene or polyethylene, which are notoriously difficult to bond.
• Durability: Label adhesives must endure extreme temperature changes, including sterilization cycles and refrigeration without degrading or detaching.
• Safety: Facestock materials must be inert and non-leaching, especially when in proximity to sensitive compounds or biological samples.

Recommended materials for mandrel applications

• Facestock: Polyethylene (PE) or polyolefin films provide the flexibility and conformability needed for tight curves. These films also hold up under extreme temperatures, making them suitable for sterilization and refrigeration.
• Adhesive: A permanent, medical-grade acrylic adhesive is ideal for securing labels to low-energy surfaces. These adhesives offer strong initial tack and long-term performance, even in demanding environments.

Adhesives that withstand medical sterilization

When pressure-sensitive adhesives are part of the device design — whether securing a nameplate, custom gasket, environmental seal or label—it’s critical to understand which sterilization process will be used and how it might affect adhesive performance.

Medical devices may undergo hundreds — or even thousands — of sterilization cycles over their lifetime, including methods like ETO, Gamma and Autoclave. Each presents different challenges for adhesive integrity, material stability and long-term reliability.

Which adhesives survive sterilization? Comparing chemistries

When choosing adhesives that can withstand sterilization, it all comes down to chemistry. Most pressure-sensitive adhesives used in medical applications fall into one of three categories: acrylic, silicone or rubber-based.

Each has unique strengths — or limitations — when exposed to the heat, moisture and radiation of sterilization processes.

• Acrylic adhesives: Resists aging, chemicals and higher temperatures. Performs well in ETO and Gamma sterilization while tolerating moderate autoclave conditions. A versatile choice for many long-term medical applications.
• Silicone adhesives: A go-to material in many medical devices, silicone adhesives offer exceptional performance under extreme heat, making them well-suited for devices that endure frequent autoclave sterilization.
• Rubber-based adhesives: A cost-effective option best for short-term or room-temperature applications. They generally lack the thermal and chemical resistance needed for repeated sterilization cycles.

Learn more about the pressure sensitive adhesives and other high performance materials iD Products converts.

Automation in medical device manufacturing and labeling

Automation is playing an increasingly important role in medical device production — from assembly processes to efficient label application. To keep up with the speed and precision of automated systems, your custom die-cut adhesive — whether it’s a label, gasket or pressure-sensitive component — must be designed to be compatible with the method of automated placement.

Key considerations for automation-ready adhesive components:

• Kiss-cut liners for easy handling: Kiss cutting keeps the liner intact while the die-cut portion is easily removed, allowing quick, accurate peel-and-place in an automated workflow.
• Machine-compatible design (I/O Integration): Labels and adhesive components should be designed to integrate with pick-and-place systems. To avoid misfeeds, jams or inconsistent peel speeds, the correct liner types and cut depths are key.
• Dimensional stability for accurate placement: Materials must have the right balance of flexibility and stiffness to stay flat during application and avoid shifting, preventing skewed or misapplied labels.

Work with a trusted medical adhesive specialist

At iD Products, we specialize in converting high-performance adhesives, facestocks, and flexible materials into custom gaskets, durable labels and precision sealing solutions. Trusted solutions, like those from 3M, are specifically engineered to maintain performance through harsh sterilization conditions and repeated use. Whether your goal is environmental protection, long-term durability or automated assembly, we can help you design a product that performs through every cycle.

Ready to solve your adhesive challenges?

Let’s talk about your next project. Complete our online form and a specialist will get back to you quickly.

Need a Printer for In-House Label Production?

iD Products is an authorized Epson ColorWorks Reseller. Whether you’re labeling medical devices, packaging or lab supplies, our specialists can help you find the right printer to meet your in-house production needs.