SECONDARY OPERATIONS

Precision Assembly & Finishing Services for Metal-Plastic Integration

At D&R Products, we offer advanced secondary operations and value-added services to support the seamless integration of plastic and metal components in high-performance medical and industrial assemblies. Our engineering team collaborates closely with clients to identify the most efficient and reliable joining and finishing methods based on the mechanical, regulatory, and economic requirements of each application.

Induction Bonding for Metal-to-Plastic Assembly

We specialize in induction bonding, a highly effective method for joining plastic hubs to metal components. This process uses localized electromagnetic heating to create a strong, consistent bond without the need for additional adhesives or inserts. Induction bonding achieves torque and shear strength performance comparable to overmolding, but with added advantages:

Cost Efficiency: Eliminates the tooling and setup costs associated with overmolding, making it ideal for both low- and high-volume production.
Thermal Precision: Localized heating prevents distortion of heat-sensitive components and preserves material integrity.
Process Control: Non-contact, repeatable bonding minimizes variation and maximizes yield.

This method is particularly beneficial for applications such as catheter hubs, surgical handles, and instrument connectors, where high strength and biocompatibility are essential.

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D&R products assembly operations

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Secondary Assembly Processes for Plastics

As part of our vertically integrated service offering, D&R also provides secondary assembly solutions for plastic components, including:

Adhesive Bonding: Controlled application of medical-grade adhesives for structural or cosmetic joins.
Solvent Bonding with Methylene Chloride: A precision bonding technique that chemically softens the surface of thermoplastics to create a fused joint without mechanical fasteners.

Each assembly method is performed under controlled conditions with appropriate fixturing, inspection, and documentation to ensure strength, alignment, and regulatory compliance.

Sterile Packaging Services

To support our clients' downstream sterilization and distribution needs, D&R offers final packaging services for medical-grade assemblies. Our packaging capabilities include:

Tyvek® Pouching: Heat-sealed sterile barrier systems using DuPont™ Tyvek® for breathable, contamination-resistant packaging compatible with EtO and gamma sterilization.
Blow Mold Packaging: Rigid packaging solutions for devices requiring crush resistance, customized tray design, and product stabilization during transit and sterilization.

Each packaging solution is tailored to your device specifications and sterilization modality, with full lot traceability and labeling in accordance with FDA and ISO 13485 requirements.

Precision Finishing & Surface Enhancement Services

To ensure optimal performance, aesthetics, and regulatory compliance, we offer a wide range of finishing services:

Welding Capabilities:
- Laser Welding for micro-precision joins
- Plasma Welding for smooth, high-integrity seams
- Resistance Welding for high-throughput, repeatable bonding
Electropolishing & Passivation:
Surface treatments to enhance corrosion resistance, smooth surface topography, and improve biocompatibility—particularly critical for stainless steel implants and instruments.
Knurling (Laser & Mechanical):
Precision knurling to enhance grip, torque transmission, or press-fit performance.
Mechanical Deburring with 10x Inspection:
Manual and automated deburring to remove burrs and sharp edges, verified under 10x magnification to ensure safe, functional finishes for clinical use.
Bead Blasting & Buffing:
Surface texturing and polishing to meet tactile, cosmetic, or friction-control requirements.
Forming Operations (Pressing, Coining, Bending):
High-precision forming processes for custom metal shaping without compromising structural integrity.
Tumbling:
Batch surface finishing to improve uniformity, remove light burrs, and create smooth, consistent part surfaces.

Whether you're seeking precision bonding, high-quality packaging, or performance-enhancing surface finishes, D&R Products offers a comprehensive suite of post-machining and assembly solutions tailored to the stringent needs of regulated medical and industrial markets.

FINAL ASSEMBLY

Precision Final Assembly & Cleanroom Integration Services

At D&R Products, final assembly is the culmination of our vertically integrated manufacturing process—where component parts, sub-assemblies, and complete medical devices are brought together under tightly controlled conditions and validated to the highest quality standards. Leveraging our extensive capabilities and regulatory expertise, we offer full-spectrum assembly services tailored to Class I, II, and III medical devices and critical industrial components.

Whether we’re building to print or collaborating on a co-engineered solution, our team ensures that each assembled unit meets the exact requirements outlined in your production specification agreement, with end-to-end process control, traceability, and certification.

Integrated Assembly & Subassembly Capabilities

D&R offers full-service mechanical and electromechanical assembly, drawing on in-house precision machining, joining, and finishing expertise. Our operations are governed by ISO 13485:2016-certified quality systems, and all assemblies are fully documented, serialized, and verified through final inspection protocols.

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D&R final assembly for medical part production

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Key services include:

Laser Marking
Permanent, high-contrast identification markings (UDI-compliant) applied to metal and polymer surfaces without compromising material integrity.

Heat Shrink Tubing Application
Precision-fitting insulation and strain relief solutions applied to wiring and tubing components in catheter and electromechanical assemblies.

Heat Staking / Induction Bonding
Non-threaded bonding techniques for securely attaching plastic and metal components, providing high pull strength and cost-efficient alternatives to overmolding.

Glue and Epoxy Application
Controlled dispensing of medical-grade adhesives and epoxies, with validated cure processes for structural or cosmetic bonding.

Ultrasonic Cleaning
Particle and residue removal using high-frequency sound waves in aqueous or solvent-based baths, ensuring biocompatibility and cleanliness for implants or instruments.

Precision Bending
Custom jigs and fixtures for consistent, repeatable bending of wires, tubing, or formed parts, supporting device shaping or deployment mechanisms.

Electromechanical Assembly
Integration of wiring, sensors, and sub-electronic components into fully functional medical or diagnostic assemblies with ESD-safe handling.

Sterile Packaging & Cleanroom Final Assembly

For devices that require sterile barrier systems or particulate-controlled environments, we offer cleanroom-based final assembly and packaging services:

Clean room Assembly Options:
- ISO Class 7 (Class 10,000): For implantable and high-risk device assembly requiring enhanced particulate control
- ISO Class 8 (Class 100,000): Suitable for diagnostic, surgical, and moderate-risk device packaging

Sterile Barrier Packaging:
- Tyvek® Pouching: Ideal for EtO or gamma sterilization-ready barrier systems
- Blister Packaging: Thermoformed tray and lidding systems for high visibility and protection

Compliance & Documentation

Every product assembled at D&R is subject to comprehensive quality assurance and full material/component traceability. We provide:

Certificates of Conformance (CoC) detailing compliance with customer-defined specifications
Lot control and serialization
Process validation records
In-process and final inspection reports