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Medical Films That Get More From the Polymers You Already Trust

Peak Nano designs and manufactures custom nanolayered films for medical, pharmaceutical packaging, and bioprocessing applications that require oxygen barrier, moisture barrier, durability, thermal weldability, and biocompatibility without giving up optical clarity.

Built on Peak Nano’s patented nanolayer coextrusion platform, our films layer existing medical-use polymers to unlock more performance in simpler structures—with fewer tie layers and no fluorinated chemistry.

Talk to a Peak Nano Polymer Architect

Medical Film Engineered Around Your Requirements

Medical films have to satisfy competing demands at once. They must block oxygen and moisture, survive sterilization and handling, seal without harmful adhesives, stay clear enough for visual inspection and patient confidence, and pass drug-contact and biocompatibility review. These requirements usually work against each other, which is why the industry relies on complex structures of 10 or more layers built from tie layers, foil, and fluoropolymers.

Peak Nano Films as a Service (FaaS) gives R&D and packaging teams another lever to pull. Instead of formulating and qualifying a new blend, Peak Nano’s polymer architects arrange the polymers you already use into a nanolayer structure designed around the performance your finished product needs.

When blends don’t work, architecture can.

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Key Performance Capabilities

Final performance depends on polymer selection, layer architecture, gauge, converting conditions, sterilization method, and application-specific requirements.

Oxygen barrier

Confining EVOH into nanolayers forms more efficient barrier crystals, designed to reach target OTR with less EVOH and fewer protective layers, while helping hold barrier performance across humidity swings.

Moisture barrier

Distributing barrier polymer across many thin layers lengthens the diffusion path for water vapor, designed to reach target WVTR (ASTM F1249) without foil and to keep packages compatible with X-ray and in-line inspection.

Durability

Tough polymers can be built into the architecture for puncture, tear, crack, and craze resistance in blister backings, device pouches, and packaging for sharps and rigid devices.

Thermal weldability

Nanolayering can lower the effective glass transition temperature (Tg) of high-Tg polymers such as COC and COP, supporting thermal bonding without solvent-based adhesives or substrate deformation.

Biocompatibility

Films are built from commercial resins with established ISO 10993 biocompatibility data, supporting your final device and packaging qualification.

Optical clarity

Drawing on Peak Nano’s optical film experience, architectures are designed to add performance while holding the clarity and low haze medical products and visual analyzers require.

Sterilization compatibility

Architectures can be developed and evaluated for steam, gamma, e-beam, or EtO sterilization requirements.

Simpler structures

Nanolayer interfaces can hold dissimilar polymers together without adhesive tie layers, collapsing complex multilayer structures toward simpler ones.

PFAS-free design

The barrier is engineered through structure rather than fluorinated chemistry, offering a path away from fluorinated polymers and coatings.

What Makes Nanolayer Architecture Different?

Conventional multilayer films deliver roughly the average of their materials. Because dissimilar polymers such as EVOH and polyethylene won’t bond on their own, converters add tie layers, foil, and coatings to meet each performance target, and every addition adds cost, complexity, and material to qualify.

Peak Nano takes a different approach: we architect the film.

Peak Nano melts two or more polymers separately, combines them into an A/B structure, and passes that structure through layer multipliers to build up to 4,096 nanolayers in a single film. At the nanoscale, the interfaces where the polymers meet become the bulk of the structure. The polymer chains interpenetrate, so the film draws on the strengths of both materials at once, without tie layers.

This architecture gives medical product teams additional design variables for balancing:

Learn More About Our Technology

Applications

Medical packaging can be engineered for applications including:

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Bioprocessing

Films for single-use bioprocess reactor bags and cold-temperature storage bags used to produce biologics, including cell and gene therapies and mRNA products. Nanolayer architecture is designed to deliver sterile barrier performance, toughness against cracking and pinholing at -80°C, oxygen barrier from less EVOH, a contact layer designed to avoid leachables and extractables, and a fluorine-free route for cryogenic storage.
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Pharmaceutical Packaging

Blister pack lidding films and contact layer for pre-filled syringe and auto-injector cartridge stoppers. Peak Nano is developing clear, thin, fluorine-free barrier films from standard resins as an alternative to PCTFE, cold-form foil, and PVdC, with added puncture and crack resistance for long shelf life. Foil-free structures also support X-ray and ultrasound authentication for anti-counterfeiting programs.
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Drug Delivery Devices

Films for syringe stoppers, plungers, auto-injectors, and pens. Peak Nano engineers fluorine-free, chemically inert, low-friction films for laminating stoppers and plungers, with low break-loose and glide force tuned for high-viscosity and large-volume drugs, plus durable shield layers that protect Class II devices and sharps through shipping and handling.
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Microfluidic Chips

Lidding, sealing, and reagent-storage films for lab-on-a-chip and point-of-care diagnostic devices. Nanolayer films are designed to combine COC/COP-class clarity with moisture barrier, refractive index control, and tuned stiffness, and to bond thermally at lower temperatures, sealing channels without solvent adhesives, chip deformation, or harm to stored reagents. The result is a lighter, less fragile alternative to glass.

Engineered for Your Packaging Process

Peak Nano develops film architecture with your converting process, sealing equipment, and qualification pathway in mind.

Supported film formats may include:

  • Blister and backing films
  • Thermoformable barrier films
  • Sterile barrier pouch webs
  • Bioprocess and cryogenic storage bags
  • Stopper and plunger laminating films
  • Microfluidic lidding and sealing films
  • Custom polymer combinations, layer counts, roll widths, and slitting on request

Film development can be aligned with requirements for thermoforming, lamination, heat sealing (heat bar, impulse, and ultrasonic), substrate pairings (COC to COC/COP, film to Tyvek, film to rigid tray, and film to film), sterilization, gauge, clarity, and package integrity.

Conventional Structures vs. Nanolayer Architecture

How nanolayer architecture changes the design approach for common medical film challenges.

Design challenge Conventional approach Nanolayer architecture approach How it gets proven
Oxygen Barrier Thick EVOH or foil layer buried between moisture-blocking layers and tie layers Confined EVOH nanolayers designed to reach target OTR with less barrier resin OTR per ASTM D3985 / F1927 across the humidity range
Moisture barrier Foil, PVdC, or PCTFE laminates Many thin barrier layers that lengthen the diffusion path, without foil or fluorine WVTR per ASTM F1249; USP 671 moisture permeation
Durability Separate puncture, barrier, and sealant layers joined by tie layers Tough polymer integrated into the architecture Dart impact and puncture testing; ASTM F88 / F1929; accelerated aging per ASTM F1980
Thermal weldability Solvent- or water-based adhesives, or COC-to-COC welds that deform the substrate Reduced effective Tg for thermal bonding without adhesives Seal and bond strength per ASTM F88; channel integrity
PFAS replacement PTFE, ETFE, PCTFE, or FEP films and fluorinated coatings Barrier and low friction engineered through structure from non-fluorinated resins Head-to-head barrier and glide force testing against the fluoropolymer benchmark
Qualification New blends require full new-material qualification Existing medical-use resins, rearranged rather than reformulated Resin-level ISO 10993 data; final device testing (USP Class VI, USP 661.1 / 665) by the device maker
Clarity Performance limited to protect clarity, or glass used instead of polymer Performance added with clarity designed in Haze, light transmission, and autofluorescence

Built for Regulated Medical Supply Chains

Peak Nano builds medical films from commercial resins supported by existing biocompatibility and regulatory data, and changes the architecture of those materials, not their chemistry. Final device and packaging qualification is completed by the device maker or brand owner, and Peak Nano supports that work with documented materials and process data.

Designing Medical Films With Less Material

Sustainability expectations are reaching medical products, and carbon costs now attach to the plastic in every device. Nanolayer architecture helps product teams reduce material at the design stage: fewer layers, less barrier resin, no foil, and no fluorinated chemistry.

For device applications without drug or blood contact, thermoplastic nanolayer structures offer a path toward thermoset-level performance in materials that can be reprocessed, and toward recycle-ready designs. Bio-derived polymers can also be evaluated within the architecture.

From Film Concept to Production

Through Peak Nano Films as a Service (FaaS), brand owners and converters work directly with Peak Nano’s experienced polymer scientists to design a custom medical film for their exact requirements, in months rather than the two years a conventional development cycle can take. Customers can enter and stay at whichever scope fits their program.

1

Define Requirements

Critical-to-quality requirements are established: target OTR and WVTR, film format, sterilization method, converting and sealing conditions, and the resins already in your regulatory filings.

2

Research

A focused feasibility study tests nanolayer architectures on your materials and performance targets, with prototype films in as little as 6 to 10 weeks.

3

Co-Develop

Peak Nano optimizes polymer composition, layer count, and process conditions to reproduce the result reliably.

4

Test & Validate

Films are evaluated against barrier, mechanical, sealing, optical, and application-specific requirements. Co-development can begin on commercial-grade resins, with final prototyping on medical-grade equivalents.

5

Scale Up

The validated architecture moves from Peak Nano’s R&D line to pilot-scale rolls.

6

Commercialize

License the design, have Peak Nano produce it at its U.S. facility, or work with Peak Nano to build your own line.

Why Medical Product Teams Choose Peak Nano

Better performance from polymers you already trust

Peak Nano engineers film structures at the nanoscale from existing medical-use polymers, not new blends. Your team gets more performance from materials already in your supply chain and regulatory filings, without taking on the risk of an unknown new material.

Less requalification, faster time to market

A new polymer blend can mean years of qualification before a product reaches patients. Because Peak Nano rearranges existing proven resins rather than reformulating them, customers can avoid much of the new-material qualification burden and move to market faster.

Simpler structures

Nanolayer architecture is designed to reduce the layers, tie layers, foil, and fluorinated materials that complex medical films rely on. Fewer components means fewer materials to source, qualify, and manage.

Performance without trading away clarity

Barrier, durability, and weldability are designed in while holding the clarity medical products require.

We do the development work

Through Peak Nano Films as a Service, Peak Nano's polymer scientists handle the R&D, from feasibility studies and prototyping through validation and scale-up. Your team defines the requirements, and we engineer the film around them.

A proven platform

Peak Nano was founded in 2016. Its nanolayer technology is backed by 20+ patents and more than a decade of research with Case Western Reserve University, DARPA, and the U.S. Naval Research Laboratory.

U.S.-based development and manufacturing

Films are developed and produced at Peak Nano's Films Development Center in Valley View, Ohio. This supports supply security and a supply chain that doesn't depend on fluorochemistry.

Frequently Asked Questions

A nanolayered medical film is built by coextruding commercial polymers into hundreds to thousands of nanoscale layers. Peak Nano’s architecture can be fine tuned based on a company’s needs to improve barrier, durability, and thermal weldability while maintaining the clarity medical products require.

Peak Nano splits the EVOH you already use into tens, hundreds, or thousands of nanolayers. At that scale, the EVOH crystals form flat sheets that oxygen has trouble getting through. This lets you hit your oxygen transmission target with less EVOH. The many layers also bond the stack together, which can reduce or remove the need for tie layers and give a simpler medical film.

Peak Nano engineers barrier through nanolayer structure rather than fluorinated chemistry. Its fluorine-free films are being developed as alternatives to PTFE/PCTFE blister films and fluoropolymer stopper films, with the goal of matching barrier and friction performance using standard resins.

Peak Nano builds films from commercial resins with existing ISO 10993 data and changes their architecture, not their chemistry, which can simplify qualification. Final device and packaging testing, such as USP Class VI and USP 661.1, remains with the device maker.

Sterilization compatibility is built into Peak Nano’s film design process. Architectures can be developed and evaluated for steam, gamma, e-beam, or EtO sterilization, with property retention confirmed for each application and polymer combination.

Tie layers exist because dissimilar polymers won’t bond. At nanoscale thicknesses, the interfaces between Peak Nano’s layers dominate the structure and hold dissimilar polymers together, helping collapse complex multilayer medical films toward simpler structures.

Yes, clarity is a core design target. Peak Nano draws on its optical film experience to add barrier, durability, and weldability while holding the clarity and low haze that medical devices, visual inspection, and analyzers require.

Peak Nano Films as a Service (FaaS) gives medical brand owners and converters direct access to Peak Nano’s polymer scientists to design, prototype, validate, and scale a custom nanolayered film, with options to license, outsource production, or build their own line.

Through Peak Nano Films as a Service, prototype films can be produced and evaluated in as little as 6 to 10 weeks. Full development and scale-up timelines depend on performance targets, materials, and the customer’s qualification requirements.

Peak Nano develops nanolayered films for bioprocessing, pharmaceutical packaging, drug delivery devices, and microfluidic chips, including freeze-thaw bag films, blister filmslidding, syringe stopper films, and microfluidic lidding and sealing films.

Develop a Medical Film for Your Application

Tell Peak Nano what your current film needs to accomplish, and which materials you want to keep.