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Material Consideration Radiation Processing

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Material Consideration Radiation Processing Material Consideration Radiation Processing The Global Leader in Comprehensive Sterilization Solutions sterigenics.com Radiation’s Effects Radiation interacts with polymers in two Stabilizers and Additives Material Evaluation ways: chain scission, which results in Additives and stabilizers are commonly When weighing the radiation stability of reduced tensile strength and elongation; and included in small amounts (less than 1%) a polymer and the ultimate success of a crosslinking, which increases tensile strength in commercial polymer products to aid in component or medical device, the following but reduces elongation. Both reactions occur processing, stabilize the material and impart factors should be taken into consideration: simultaneously, but one is usually dominant, particular properties to the product. depending upon the specific polymer and • Stabilizers and antioxidants added to additives involved. Tint-based, multi-function stabilizers, for a polymer can reduce the effects of Chain scission classically affects stressed example, are added to PVCs to counteract the irradiation on the product’s mechanical polymers (containing residual molding stress) to a color change that is typical when this material properties and/or physical appearance greater extent than non-stressed polymers. The is irradiated– an important consideration in • Thin part sections, thin films and fibers combined impact of solvent-induced stress, situations where color plays a strong role in present in a component or product can allow residual molding stress and applied load acts to customer reaction to the product. Other additives for excessive oxygen exposure during the intensify radiation damage. known as “antirads” function as antioxidants irradiation process, thus causing degradation and help prevent radiation damage. of the polymer material Generally, polymers containing aromatic ring structures (e.g. polystyrene) are resistant to These additives perform either as reactants, • Residual mold stress present after molding radiation effects. Aliphatic polymers exhibit which readily combine with radiation- and assembly of a component or product degrees of resistance depending upon their generated free radicals within the polymer, or can promote molecular scissioning during levels of unsaturation and substitution. as primary energy absorbers, preventing the irradiation interaction of the radiation energy with the Some effects of radiation–such as reduced polymer itself. • Highly oriented moldings, which are strong elongation due to chain scission, may detract in the axis of orientation but are already from the device’s performance. Others can very weak in the cross-flow axis, will be beneficial. For example, crosslinking of become weaker after irradiation polyethylene and silicones increases tensile • High molecular weight polymers having strength. low melt flow will survive radiation better Manufacturers should be cognizant of the by providing longer molecules and stronger possible impact of radiation on mechanical parts before and after irradiation. properties such as tensile strength, elastic modulus, impact strength and elongation. Outcomes may influence performance and should be evaluated in advance by functional testing. Material Compatibility TABLE 1 and Validation PHYSICAL AND FUNCTIONAL TEST METHODS FOR PLASTICS MATERIAL EVALUATION Each polymer reacts differently to ionizing radiation. Thus, it is important to verify that the Test Method Test References maximum administered dose will not have a detrimental effect on the product’s function or Test for Embrittlement the patient’s safety over the product’s intended 1. Tensile properties shelf life. a) Tensile strength ISO 527 series Experimental samples of the product should b) Ultimate elongation ISO 527 series be irradiated to at least the highest dose to be encountered during routine processing. c) Modulus of elasticity ISO 527 series For example, a product which is to receive a d) Work ISO 527 series sterilizing dosage of 25 to 40 kiloGray (kGy) should be tested by dosing samples to at least 2. Flexural properties 40 kGy. A conservative approach is to irradiate Stability of Irradiated Polypropylene 1. Mechanical Properties, Williams, Dunn, Sugg, Stannet, Advances in Chemistry Series, No. samples at doses up to twice the anticipated a) Flange bending test maximum dose. 169, Stabilization and Degradation of Polymers, Eds. Allara, Hawkins, pp. 142-150, 1978. Since various product applications call for b) Flexbar test ISO 178 certain performance properties or functional characteristics, it is important to test each 3. Impact resistance ASTM D-1822 component or product in an appropriate 4. Hardness manner, using both new and aged material. a) Shore ISO 868 Table 1 reviews typical tests of physical b) Rockwell ASTM D-785 properties. Other tests, which more closely approximate the actual mechanical application, 5. Compressive strength ISO 604 may also be employed by the engineering or 6. Burst strength ASTM F-2054 research staff. 7. Tear strength ASTM D-1004 and ISO 6383-1 Results of the evaluation should be retained Test for Discoloration in the product’s device history file, serving as physical confirmation that all product claims 1. Yellowness index ASTM E-313 and specifics have been met. If product testing 2. Optical spectrometry ASTM D-1746 indicates a potentially adverse effect from high levels of radiation, a maximum permissible dose Source: International Atomic Energy Agency. Guidelines for industrial radiation sterilization of disposable medical products. Co-60 should be established by the manufacturer gamma irradiation. TEC DOC-539. Vienna IAEA, 1990. and emphasized in the specific processing instructions to the contract sterilizer. Figure A graphically displays the dose FIGURE A ranges at which a number of common RELATIVE RADIATION STABILITY OF MEDICAL POLYMER “FAMILIES” thermoplastics and thermosets show significant change in properties Thermosets (i.e., a 25% loss in elongation). Loss of Polystyrene elongation is a commonly used measure Liquid crystal polymer of the effect of irradiation because Polyurethanes Polyethylenes it equates to a brittleness failure. Polyesters Polycarbonate This figure also provides a visual means HP Engineerring Resins of making an initial estimate of a polymer’s Silicones ability to withstand a particular radiation PVC sterilization process. Polyamide (nylons) ABS PMMA PP (Stabilized) Polymethyl Pentene Elastomers Cellulose Polypropylene (National) FEP PTFE Acetals 0 10 20 30 40 50 60 70 80 90 100 kGy Compatible Use with Caution Not Recommended NOTE—HP = high performance; PVC = polyvinylchloride; ABS = acrylonitrile butadiene styrene; PMMA = polymethylmethacrylate; PP = polypropylene; FEP = fluorinated ethylene propylene; PTFE = polytetrafluoroethylene. TABLE 2 GENERAL GUIDE TO RADIATION STABILITY OF MATERIALS Table 2 shows typical radiation resistances of medical polymers in stress-free parts measured at the point where 25% of the polymer’s elongation is lost because of radiation. This circumstance might well be the “best case.” If the part being considered has a significant degree of residual stress as a result of manufacture, the dose at which the 25% loss of elongation occurs can be considerably lower. (•) = poor (••) = fair (•••) = good (••••) = excellent (NL) = not likely (L) = likely Single use Resterilization Material Comments Comments (<50 kGy) (<100 kGy) Thermoplastics High-impact grades are not as radiation Acrylonitrile butadiene styrene (ABS) ••• resistant as standard impact grades because L of the higher butadiene content. Fluoropolymers When irradiated, PTFE and PFA are significantly damaged. The other Polytetrafluoroethylene (PTFE) • fluoropolymers show significantly greater NL stability. Some (for example, PVDF) are excellent. Perfluoro alkoxy (PFA) • NL Perchlorotrifluoroethylene (PCTFE) ••• to •••• L Polyvinyl fluoride (PVF) ••• L Polyvinylidene fluoride (PVDF) ••• to •••• L Ethylenetetrafluoro ethylene (ETFE) ••• to •••• L Fluorinated ethylene propylene (FEP) •• NL Irradiation causes significant chain scission (i.e., Polyacetals (e.g., polyoxymethylene) • embrittlement). Color changes have NL been noted (yellow to green). Polyacrylates (e.g., polymethylmethacrylate) •• to ••• NL Very dependent Nylon 10, 11, 12, and 6-6 are more stable than Polyamides (e.g., nylon) •• to ••• L on design and use 6. Nylon film and fiber are less resistant. requirements. Yellows—mechanical properties are not Polycarbonate (PC) ••• to •••• greatly affected; colorcorrected radiation L formulations are available. Polybutylene terephthalate is not as Polyesters, saturated •• to ••• radiation stable as polyethylene L terephthalate resins. High-density polyethylene is not as stable as mediumdensity polyethylene and Polyethylene (PE), various densities ••• to •••• L low-density polyethylene, linear lowdensity polyethylene. Polyimides (e.g., polyetherimide) •••• L Polyketones (e.g., polyetheretherketone) •••• L TABLE 2 (Continued) GENERAL GUIDE TO RADIATION STABILITY OF MATERIALS (•) = poor (••) = fair (•••) = good (••••) = excellent (NL) = not likely (L) = likely Single use Resterilization Material Comments Comments (<50 kGy) (<100 kGy) Polypropylene (PP) Physical properties are greatly reduced when irradiated (for example, chain scissioning). Radiation-stabilized grades, using high molecular weight, copolymerized Natural • to •• and alloyed with polyethylene, with additional NL stabilizers should be used in most radiation applications. Use of electron beam
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