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

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
  • 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