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Polymer Solution Casting

Avalon polymer solution casting™ utilizes liquid polymers to produce superior tubing for medical devices.

Polymer solution casting methods allow us to incorporate materials with different properties including strength, lubricity, flexibility, color and multi-lumens - to customize tubing for any application.

Avalon has a full team of engineers that create uncompromising, cost-effective medical devices. Engineering expertise includes development, manufacturing, quality and material science.

Product Development and Manufacturing Options


  • Single lumen
  • Dual lumen
  • Multi-lumen
  • Co-axial
  • Complex geometric designs
  • Tapered designs
  • Bump tubing
  • Bending/shaping/forming
Embedded Reinforcement/Features
  • Braiding (flat, round wire)
  • Coiling (flat, round wire)
  • Hypotubes
  • Malleable and laser cut wires
  • Medical grade stainless steel or nitinol
  • Radiopaque/imaging targets (marker bands, tantalum dots, etc.)
  • Sensors, electronics
Wall Thickness
  • Continual and multi-layered wall thickness over the length of the tube/product
Dual/Multi - Durometers
  • Flexible to rigid durometers over the length of the tube/product (intermittent layers)
Hubs, Luers, Caps and Connectors
  • Custom or Standard Colors
  • Hub bonding
Holes, Ports, Orifices
  • Round holes
  • Custom holes
  • Skived side holes
  • Solution compounding
  • Jacket materials
  • Liner/substrate materials
  • Custom blends
Secondary Operations
  • Bending/forming/shaping
  • Drilling
  • Etching
  • Flaring
  • Grinding
  • Hole punching
  • Hub or tip bonding
  • Skiving
  • Tipping or tip forming
  • Pad printing
  • Color variety
  • Branding
Sterilization and Packaging 
  • Pouching
  • Packaging
  • Labeling
  • Sterilizing

Materials Expertise
Avalon's experienced material engineers work with customers to get the right material properties to meet a medical device performance and design needs.

Materials processed include:

  • Polyurethanes
  • Polyvinyl Chloride
  • Silicone Urethane Copolymers
  • Custom Formulations, Compounds and Blends
  • Custom Colors