Ultimate Guide to Surgical Films: Types, Uses, Benefits & more

Surgical films are versatile and used for a wide range of functions in the healthcare industry. Medical professionals use adhesive films for surgical procedures, post-op recovery and general wound care.

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This guide covers types of surgical films and their medical applications. You will also learn about how specialised adhesive films are conceptualised and manufactured.

If you don’t know enough about surgical films quite yet – start reading to learn more!

Surgical adhesive films are used in a wide variety of medical applications. Surgical films are usually applied during abdominal surgery (for example, a common use is during a cesarean procedure). Adhesive films are used during surgery for a few key reasons.

For one, they protect surrounding areas of skin during operations maintaining a sterile environment for surgical glue and incisions during procedures. They also resist bodily fluids and other outside contaminants.

Medical professionals also use medical adhesive films in wound care to maintain an environment that promotes healing. They can also prevent physical damage and interaction with contaminants.

Adhesive films may also be used to fix medical devices to the body for patient monitoring and procedures. Let’s cover the applications for medical adhesive films and why they are vital in the medical industry.

An incision film, also known as an incise drape, is used during a surgical procedure to provide sterile protection to the skin surrounding a surgical incision and to maintain a surgical glue’s sterile environment during operations.

Incision films are designed for all types of procedures, including abdominal surgery, neurosurgery, orthopaedic surgery, plastic surgery, paediatric surgery and more. 

Silicone adhesive dressings create an immediate stable seal around skin surrounding wounds – unlike acrylic adhesive films which become more adhesive over time.

They are particularly useful for those with fragile, dry skin and are considered very comfortable.

They also won’t attach themselves to moist surfaces, ideal for a variety of wound care applications.

Soft silicone adhesives also can’t be absorbed by the body, limiting adverse effects (like an allergic reaction)influencing a wound or its surrounding skin. 

A foam adhesive dressing is comprised of two absorbent layers – a polyurethane pad and a polyurethane membrane. It is also surrounded by a pressure-sensitive acrylic adhesive border. They are designed to care for moderate to heavily exuding wounds.

The polyurethane foam padding absorbs exudate, ensuring that it doesn’t return to the wound or cause maceration (the breaking down of skin tissue due to prolonged exposure to moisture).

The polyurethane membrane ensures transpiration during recovery while providing a physical protective barrier that’s waterproof. 

Hydrogel dressings are semi-occlusive (semi-permeable) and made of hydrophilic polymers with a high (90%) water content. They are typically applied to care for wounds that are dry to moderately exuding.

Hydrogels provide a moist environment for cell migration and the absorption of some exudate.

They promote a breathable environment for effective wound healing. However, they still prevent external fluids from coming into contact with a recovering wound. 

Surgical adhesive films for procedures and other medical adhesive dressings for wound care provide a range of benefits.

In short, they are essential for conducting safe and effective procedures, fixing medical devices as well as protecting wounds and ensuring the right environmental controls for recovery.

Let’s jump into the specific benefits of medical adhesive films for surgery and patient care. 

The specialised adhesive and material barriers that surgical films provide are resistant to fluids and contaminants – making them essential for surgical procedures and wound care applications.

Their resistance to fluids also makes them easy to sterilize with solutions during medical procedures. For surgeons, these adhesive films are the first line of defence against early infections.

During recovery and wound care, adhesive films are essential for effective healing. Once bacteria settle on an open wound, the wound provides the right environment for bacteria to multiply.

Your body will attempt to fight off infection from initial bacteria, but once bacteria have multiplied it becomes harder for the body’s immune cells to clear bacteria and associated infections.

It’s easy to understand why adhesive films are so essential to ensure safety during surgical procedures and postoperative recovery periods. 

Due to the nature of surgical films being used in various medical applications – there are certain considerations when selecting core materials and adhesives.

Medical adhesive films in wound care might be made of materials that are more breathable while surgical films must be resistant to fluids.

Adhesive films for other medical devices and equipment may need materials that are stronger than others, providing durability and support.

Materials made to produce medical adhesive films can include polyethene, polyethene terephthalate, polypropylene, polyvinyl chloride, polyurethanes and other substrates.

We prefer to use high-performance polyurethanes to develop our surgical films. The right wound care manufacturer can also laminate onto synthetic non-wovens, wovens, or any textiles and integrate single-layer or multilayer constructions.

Surgical films can be pressure-sensitive or temperature-sensitive depending on their intended application.

A heat-activated adhesive will not bond at normal temperatures, however, once applied to a surface that emits natural heat (like the body’s skin) – the rise in temperature causes specific chemicals to form a bond with the contact surface.

During application, a degree of pressure may need to be applied to assist in forming an even, steadfast bond between the film and a surface. 

The key function or purpose of your medical device will guide the adhesive and backing types required for the application.

Depending on the application, you may need to select specific adhesives.

For example, a wound care product that will be placed on the elbow joint will require a great degree of flexibility and durability.

This might not be the case for other adhesive films placed elsewhere on the body, or varying applications.

Surgical films used for procedures may need to form a stronger bond with the skin than others, being able to withstand bodily fluids and other external contaminants. This will require specific skin-friendly adhesives that exclude toxic or harmful elements. 

For wound care, it is essential that medical adhesive film dressings maintain a clean environment free from outside contaminants, fluids and environmental irritants.

The materials for medical adhesive films intended for wound care need to promote a healing environment.

For example, types of adhesive films may need to be created with the right materials and adhesives to promote the breathability of wounds and injuries.

Long term recovery of wounds requires a process known as autolytic debridement – which involves the softening of tissue by the body’s processes and enzymes – to take place and this process favors a breathable environment.

Medical adhesive films are crafted with particular substrates and perforation to create different levels of breathability for wound care and injury recovery applications.

Transparent medical films are also effective for monitoring the status of a healing wound without the need to remove wraps of bandaging. Specific injuries might require less exposure to the outside air than others.

The purpose behind the medical application intended for a surgical film will guide the adhesive, substrate and accompanying elements necessary for production.

Whether your medical adhesive film will be used to accompany wound dressings, secure medical devices and equipment, or be used during surgical procedures will ultimately determine the strength of materials, type of adhesive you require and it will inform the overall design of the product.

There are various components to be considered when designing surgical films.

Are you interested in learning more about custom surgical tape? Contact us today to secure an expert consultation!

A medical adhesive film comprises a layer of polyurethane (or another substrate), a specialised adhesive, release liners, finger-lift areas, handling bars for branding, and packaging.

Polyurethanes are used for a large number of applications not limited to the medical industry – packaging, furnishings, electronics, flooring, boating, construction, clothing and the automotive industry.

Surgical films also need appropriate packaging that is sterile and ready for application.

Producing surgical films and a final packaged product that can be safely subjected to the strict sterilization procedures required for medical products (such as gamma and ETO sterilization) is essential.

It is the industry standard that medical products are subjected to gamma and ETO sterilization procedures, and once subjected to sterilization a medical product’s physico-chemical properties and its effective medical application can be affected.

Medical products require strict sterilization procedures that don’t involve the use of fluids, raised temperatures, and can’t leave minimal or any residue. Of course, design elements such as your branding, colour scheme and information about your product specifications need to be considered when designing your packaging. 

Surgical adhesive films require strict certifications to be used for different medical applications.

The medical industry requires that medical adhesive films have CE marking aligned with the EU Medical Device Regulation (MDR) /745.

Finding a medical producer that has obtained ISO is essential to ensure that they have the proven ability to create high quality, approved medical devices.

Other international standards may be applied, including ISO -5 and ISO -10 which cover aspects related to adhesives being tested for cytotoxicity, skin irritation and skin sensitization. 

The cost of manufacturing surgical film dressings is variable depending on the quantity of the order and the design of the packaged product.

It’s hard to estimate the cost to manufacture surgical films without knowing your specific requirements and medical applications for which they are intended.

We would recommend contacting us to find out more. We manufacture our medical products in cleanrooms produced and maintained under ISO standards and in alignment with industry-standard certifications.

Another consideration when producing surgical films is the process behind converting your intended materials into a high quality finished product that adheres to strict production standards.

The manufacturing process is multifaceted and involves intricate crafting processes that meet components characteristics, shape, format and application – while ensuring the right adhesive is chosen so the product can succeed in its medical application.

Here are the three main elements of the manufacturing process:

Medical adhesive tape (or surgical adhesive tape) is used for a variety of medical applications – from holding an incision closed before stitches, to attaching bandages to wounds, or as a replacement for stitches, fixing medical devices to the body and more.

Due to the wide range of applications for surgical adhesive tape, a medical manufacturer needs to provide a wide variety of lengths, widths, materials and styles of tape to suit your application.

Some of the most common adhesives used for surgical films include acrylics, epoxies, silicones, styrene block copolymers, and PSAs.

Keep in mind that adhesives for surgical procedures may need to be hypoallergenic, withstand repeatable skin contact, sterilization, conform to custom shapes and surfaces, contain elongation properties, and meet other standards.

Pressure sensitive adhesive tapes which lend themselves to laminating operations during conversion are commonly manufactured in the form of transfer tapes, single coated tapes or double coated tapes. 

These converted products each aim to improve the quality of a product and ensure effective application, while reducing cost.

We convert surgical tape into specifically sized rolls, and die cut or slit tape to fit your needs.

Our expertise and knowledge help us inform businesses about the best product based on performance and pricing. Our team has the skills and know-how to handle and convert medical tape products to your exact requirements.

We are able to source and provide reduced lead times for samples, prototypes and full orders of surgical tape. We use a wide range of tape products to create bespoke solutions for our clients.

Die cutting is the process of using a die (a specialized machine tool used to cut material to a desired shape) to cut materials such as fiber, cloth, paper, and pressure-sensitive adhesive tapes amongst others.

To produce a die-cut, certain parameters need to be assessed such as material type, tolerance, volume, and final presentation required. Once these have been assessed and the feasibility of producing the required die-cut ascertained, the machine and tool type is then selected

There are different types of die cutting methods available to suit various materials. Flatbed medical die cutting, rotary medical die cutting and large format die cutting.

This machine is fitted with an extensive range of innovative capabilities that makes it possible to configure a range of medical devices, providing almost endless possibilities in terms of presentation, style and format.

Rotary medical die cutting can be combined with lamination, multi-layer substrates, printed backing papers and sheeting in a single pass. Capabilities also include perforation of materials to aid breathability and product design.

Your prospective medical manufacturer needs to instill complete confidence in their abilities. An established track record indicating expertise and experience producing high quality medical devices in alignment with international standards is crucial.

VETTING YOUR MEDICAL MANUFACTURER is a great way to ensure that the specifications of your medical device are met in full.

We would suggest reviewing their references, medical partnerships and consider getting sample products produced for your reference.

We are a contract manufacturer of medical devices for the global healthcare market – ranging from advanced wound care products to ground-breaking diagnostic applications. We deliver fully qualified products within limited turnaround times that adhere to the ultimate quality standards for various markets around the world.

CONTACT US to find out more about our medical manufacturing capabilities to suit your application!

In the realm of healthcare, precision and care go hand in hand, particularly in the management of post-operative and general patient care. A pivotal component often overlooked in this equation of optimal medical care is surgical tape. While its role might appear minimal, the selection of the appropriate surgical tape can significantly impact patient outcomes.

Understanding the Essence of Surgical Tape

Surgical tape is a critical tool in medical care designed to secure wound dressings and medical devices to the skin. This adhesive strip ensures that bandages stay in place, keeping wounds protected from contaminants. Unlike ordinary adhesive tapes, surgical tape is specifically engineered to be gentle on sensitive skin while maintaining effective adhesion.

Diversifying Your Options: Expanding on Surgical Tape Classification

Surgical tapes come in various classifications, catering to a wide range of medical needs. These include:

• Microporous Tape: Highly breathable and adaptable, it is perfect for delicate skin.
• Silicone Tape: Designed for easy removal, making it ideal for patients with sensitive skin.
• Elastic Tape: Offers flexibility, ideal for areas that require movement.
• Zinc Oxide Tape: Known for its robust adhesion and is often used for supporting joint injuries.

By understanding these categories, healthcare providers can match the tape to specific patient needs, enhancing care quality.

Exploring the Backbone: Composition and Materials of Surgical Tape

The choice of materials in surgical tape production plays a pivotal role in its function and effectiveness. Common materials include paper, silicone, cloth, and polyethylene films, each providing distinct benefits:

These materials ensure that surgical tapes cater to diverse medical scenarios, from securing tubes to holding bandages in place.

Scenarios in Focus: Unveiling the Diverse Applications of Surgical Tape

Surgical tapes find themselves at home in various medical scenarios. They are indispensable during surgeries to secure surgical dressings and during recovery for dressing retention.

Consider a case where a patient has undergone knee surgery. Using elastic surgical tape offers the perfect blend of support and flexibility, allowing the patient to move naturally without risking the integrity of the dressing.

The Bigger Picture: Weighing Pros and Cons for Informed Decisions

Like any medical tool, surgical tapes come with their lineup of advantages and disadvantages. On the upside, they offer simplified application, minimize skin trauma, and guarantee wound protection. However, the wrong choice or misapplication can result in skin irritation or inadequate adhesion.

For instance, a well-known manufacturer’s silicone tape might work wonders for a patient with fragile skin but fall short in high-moisture conditions where polyethylene tape would excel.

In Conclusion: Elevating Patient Care through Informed Surgical Tape Selection

The critical takeaway from understanding surgical tape lies in its impact on patient care. Being informed about the materials, types, and appropriate applications empowers healthcare professionals to make choices that enhance patient outcomes. The right surgical tape is not just an accessory but a cornerstone of effective wound management.

Frequently Asked Questions

Q: How do I choose the right surgical tape for a patient with sensitive skin?
A: Opt for silicone-based tapes, known for their gentle adhesion and pain-free removal, ensuring minimal skin trauma.

Q: Can surgical tape be used in wet environments?
A: Yes, polyethylene-based tapes are suitable for wet conditions due to their water-resistant properties.

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