Medical plastics underpin reliable healthcare

Five to six out of every ten medical products and devices used in hospitals, medical practices and everyday care are made of plastics. Applications include syringes, needles, tubing, implants and packaging. The materials support hygiene, technical development and efficient production across modern healthcare. "Approximately 50 to 60 percent of all medical devices are made of plastics," the German Medical Technology Association (BVMed) concludes.

The role of plastics in the sector has expanded over recent decades. "The importance of plastics in medicine has steadily increased over recent decades. They are used in a wide range of applications, including disposable products, implants, packaging, and medical devices," says Manfred C. Beeres, spokesperson for BVMed.

Market research firm Grand View Research expects the global medical plastics market to reach USD 87.58 billion by 2030. This would be equivalent to nearly one quarter of Apple's annual revenue in fiscal year 2025.

Defined requirements for medical-grade plastics

Plastics intended for healthcare applications must meet demanding requirements and are commonly described as medical-grade plastics. Their suitability depends not only on the base polymer, but also on controlled composition, processing and performance under conditions associated with a specific medical application.

"Medical-grade plastics are materials specifically selected and qualified for medical devices and medical applications. They meet defined requirements regarding biocompatibility, formulation consistency, sterilizability, and quality," explains Sarah Janczura, spokesperson for the Association of German Engineers (VDI). "These properties are essential for safe and reliable performance in medical environments."

VDI Guideline 2017 on medical-grade plastics defines criteria and provides a basis for their safe application.

Functionalization expands material performance

Material development is extending the properties available to medical product manufacturers. "Functionalized plastics transform a standard material into a component with added value: they can be sterilizable, flexible, and high-strength; chemically resistant; biocompatible; or specifically optimized for low friction," explains Benjamin Redlingshöfer, Director of the Thuringian Institute for Textile and Plastics Research (TITK).

According to Redlingshöfer, these properties can support safer production of smaller and lighter medical devices, while also improving cost efficiency. Functionalization can also address microbiological risks. "Antibacterial, antiviral, or antifungal properties reduce the microbial load on surfaces and lower the risk of biofilm formation and subsequent infections, particularly during prolonged use or frequent contact," he notes.

Patient-specific production and processing efficiency

Plastics can be used to manufacture individualized prostheses, heart valves and joint components. Processes such as injection molding enable precise production for defined therapeutic requirements. Additive manufacturing further extends the scope for customization.

"New developments, such as 3D printing, allow for patient-specific implants and components that can be manufactured with exact precision," says Beeres. These production options support the development of personalized medical solutions.

Low weight is another factor in material selection. Plastics are "significantly lighter than metal or glass, making them easier to handle. In mass production, unit costs decrease. Processing metal and glass can be more expensive," Janczura says.

Durable designs and recyclability can also contribute to more responsible resource use. Across applications ranging from disposable products and packaging to implants, plastics combine defined safety characteristics with design flexibility and production efficiency.