Custom Polymer Application Development
Our material development process leverages nearly four decades of expertise, starting with your unique biomedical innovation vision. We specialize in customizing and developing high-performance polymer solutions, partnering with you from the earliest design phase. Whether you’re just starting with a concept or preparing for large-scale production, you'll receive comprehensive, structured support and expert guidance in materials selection, manufacturing processes, and rapid prototyping — ensuring speed, precision, and reliable results.
Proof of Concept: Turning Ideas into Reality
Validating your concept is critical before investing in large-scale development. We offer agile, small-batch proof-of-concept services to quickly assess the feasibility of new materials, colors, formulations, and processes.
Using our state-of-the-art Innovation Center and equipment, we help you:
- Explore new polymer formulations and processing methods
- Evaluate material performance
- Create early-stage prototypes for design and functionality testing
Our rapid turnaround times and expert guidance help you make informed decisions faster, reducing risk and accelerating innovation.
Process Development & Scale-Up: Concept to Production
Taking a product from lab scale to production requires precision and planning. Our objective is to streamline your scale-up process, reduce risks, and optimize time, cost, and resource efficiency as you move towards commercialization. Foster’s process development services ensure that your formulation can be scaled efficiently without compromising critical to quality (CTQ) attributes. We achieve this by conducting scalable trials to fine-tune parameters and guarantee consistent results. When necessary, we apply advanced process techniques, such as DOE, to enhance outcomes.
Validation: Ensuring Confidence and Compliance
Regulatory standards and product reliability are critical in medical applications. Our comprehensive validation services confirm your product performs as expected and meets the required guidelines. We tailor solutions to your specific needs, including both Operational Qualification (OQ) and Performance Qualification (PQ), ensuring that your product and processes are fully optimized for production.
Operational Qualification:
Operational Qualification is the first step, evaluating the operational performance of your system. During OQ, we process the compound under varying conditions — low, nominal, and high — to ensure the system operates within predefined limits. This thorough testing identifies potential issues or process variations, guaranteeing your system can achieve consistent and efficient operation upon scale-up.
Performance Qualification:
Performance Qualification verifies the actual performance of materials and systems in production. During this phase, we assess how varying the raw material inputs impacts the final product attributes. PQ ensures that, regardless of material variation, your product consistently meets desired specifications and performs as expected in real-world applications.
Our validation capabilities include mechanical and physical property testing (tensile, flexural, impact), color and visual assessments, and friction and lubricity testing. With our support, you gain assurance that your product is rigorously tested and prepared for market approval.
Commercialization & Production: Scalable, Reliable Manufacturing
When it’s time to bring your product to market, Foster delivers scalable, high-quality commercial production solutions. Our manufacturing processes are designed for consistency, traceability, and speed, helping you meet market demands and maintain product integrity.
