Introduction
Intravenous (IV) therapy is essential in clinical care, yet risks such as air embolisms, backflow, and catheter-related infections persist. Axiflow’s sintered porous plugs offer a passive, failsafe solution—engineered with precision polyethylene matrices that deliver both high particulate filtration and consistent fluid flow within safety catheters.
1. Dual-Function Porosity: Filter & Vent
A carefully calibrated pore structure (2–10 µm) enables effective filtration of particulates ≥2 µm while ensuring smooth fluid passage. Optional hydrophobic-to-hydrophilic gradients provide a self-sealing effect—fluid flows under normal infusion pressure, while air bubbles are repelled, significantly reducing the risk of embolism.
2. Medical-Grade Materials & Biocompatibility
The plugs are manufactured from USP Class VI and ISO 10993-validated HDPE, free from plasticisers and processing aids that could leach. Elemental impurities are maintained at <1 ppm total heavy metals. For drug-contact applications, Axiflow also offers an inert FEP-coated variant.
3. Sterile-Ready Supply Chain
Plugs are supplied EtO-ready or can be gamma sterilized in-house. A dimensional Cpk > 1.33 is ensured through automated weight and vision inspection systems, maintaining push-fit retention force within ±5%—a critical parameter for automated catheter assembly processes.
4. Laboratory & Clinical Validation
Pressure-drop tests (ISO 8536-4) confirm <8 kPa at 250 ml/h flow rates. Bacterial ingress testing with Staphylococcus aureus demonstrates a 6-log reduction over 24 hours. Human factors trials confirm that self-sealing variants respond in under 1 second upon disconnection, preventing leakage and external contamination.
5. Design for Manufacturability Support
Axiflow’s R&D team offers CFD simulations and FMEA-based design optimization, accelerating OEM development cycles. Custom features such as overmoulded flanges, color-coded identifiers, and RFID inlays can be integrated during sintering to streamline downstream operations.
Conclusion
By combining advanced materials science, medical-grade compliance, and customizable engineering, Axiflow’s porous plugs enhance IV catheter safety while supporting scalable, cost-efficient production. Backed by decades of expertise in porous technologies, our team ensures responsive, reliable partnership for OEMs worldwide.