Advances in biotechnology have led to the development of needle-free procedures as an appealing option for delivering health-saving vaccinations. At Plastikon, we served as an end-to-end production source for the medical device highlighted here, which serves to properly prepare the skin for the consistent and effective application of a transcutaneous vaccine patch.

Effective process engineering was critical for this project in terms of both quality and throughput speeds. In addition to injection molding the components, we were also responsible for printing, assembly, and packaging 150 million units in a six-month time frame. We developed work cells that incorporated four 500 ton presses and eight 300 ton presses supported by robotics, conveyor systems, auxiliary equipment, as well as vision and cavity pressure monitoring systems for in-line quality control and verification. We synchronized the molding, ultrasonic welding, pad printing, and assembly to coordinate a smooth flow of product, which we packaged into die cut foil wrappers.

Featuring finished dimensions of 75 mm in length x 25 mm in width, closely supervised processing enabled us to achieve ± 0.08 mm tolerances. To learn more about this project, or how our extensive industry experience and innovative manufacturing processes can serve the global healthcare market, contact us today.

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Highlights of the Healthcare Device Assembly

Product Description/Scope

  • Pretreatment for Vaccine Patch

Contract Manufacturing
Capabilities Applied/Processes


  • Process Engineering
  • Tooling
  • Project Management
  • Component Sourcing
  • injection Molding
  • Ultra Sonic Welding
  • Die Cutting for Foil Packaging


  • Pad-Printing
  • Assembly
  • Packaging

Equipment Used to Manufacture Part

  • 4 – 500 Ton Presses, and 8 – 300 Ton Presses.
  • Each machine supported by Robot, Conveyor, Auxiliary Equipment, and Camera, for continuous visual quality check.

Overall Part Dimensions

  • 75mm x 25mm

Tightest Tolerances

  • ±0.08

Material Used

  • ABS/PC7800M-9000

In process testing/inspection performed

  • Dimensional Inspection, Visual Inspection, Cavity Pressure Monitoring

Industry for Use

  • Health and Human Services


  • 150,000,000

Delivery/Turnaround Time

  • 6 Months

Delivery Location

  • Washington D.C.

Standards Met

  • Customer Specifications

Product Name

  • ELT205-SPS Devices