HOW IT’S MADE

Utilizing our proprietary hydrogel technology, NEXGEL provides custom manufacturing solutions to partners in the medical device and cosmetic industry.

Hydrogels are gel-like or colloidal substances made of water and solids and are primarily used for medical and cosmetic purposes.

HYDROGEL APPLICATIONS

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    Transdermal
    drug delivery

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    WOUND
    CARE

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    COMPONENTS FOR
    MEDICAL DEVICES

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    COSMETIC PATCHES
    & MASKS

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    Conductive &
    NON-CONDUCTIVE
    ADHESIVES

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    TEMPERATURE
    MANAGEMENT

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    MEDICAL
    DIAGNOSTICS

Manufacturing process

NEXGEL hydrogels are manufactured by using a hydrophilic polymer that can mix with or dissolve in water to create a feed mix. The feed mix is then coated onto a liner and exposed to radiation. The polymers, when exposed to ionizing radiation, cross-link faster and then settle to create a matrix that gives the gel a solid form.

Active ingredients such as over-the-counter medication, skincare, wound-healing or other materials can be added before or after the cross-linking procedure. Elements that do not survive the radiation process, or are modified, are added once the cross-linking process is complete.

Once the gels have been mixed and cross-linked, they form sheets that can be delivered directly to the customer or cut to shape according to the appropriate specifications. Many of the processes described above are proprietary to NEXGEL, which gives us a competitive advantage: Producing high-quality products with great flexibility to customize products based on our customers’ needs.

Advantages of Electron Beam Cross-Linked Hydrogels

Hydrogels can be made two different ways: chemically through a combination of ultraviolet cross-linking and chemical interface, or by exposing a specific polymer mixture to ionizing radiation. This creates a hydrogel sheet having a very high water content.

The cross-linking of hydrogels can be further modified by varying the percentage of polymer cross-linking and the way in which the high energy field is delivered. There are three variables in the use of an electron beam accelerator for cross-linking of hydrogels.

  • Allowing for precise control of the amount of polymer cross-linking
  • Preventing the need for chemical cross-linking agents which may interfere with other additives or active ingredients
  • Providing the ability to consistently manufacture high-quality hydrogels
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    Time of exposure of
    the target material to
    the electron stream
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    Voltage
    (electrical potential)
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    Amperage
    (strength of the
    electrical current)

What Makes NEXGEL’s Hydrogels Unique

Unlike many of the other patches on the market today, NEXGEL’s hydrogels are always uniform, possess a high water content, and never have active receptivity issues. Our Hydrogels feature chemical and form stability so you can rest assured that the method of delivery is safe and consistent across the board.

We know how important it is to maintain skin-friendly ingredients in our patches, this is why our patches do not aggressively bond to the skin or have strong odors. The method of delivery should never interfere with the end result.

  • Mixing

    Our feed mixes feature far greater homogeneity than those of our competition. This manufacturing advantage is critical, especially as it relates to dosages of active ingredients. Our proprietary mixing technology allows for the incorporation of sensitive materials that may degrade if subjected to other types of mixing.

  • COATING

    Our proprietary coating technology enables us to properly coat the gels even though the gels are extremely thick and resistant to flow. We have achieved coating tolerances that have allowed us to coat materials as thin as 0.010 of an inch with a margin for error of typically less than 5%. Thickness controls are critical with respect to the performance of many of the end products utilizing our hydrogels, including medical electrodes, transdermal delivery patches and cosmetic patches.

  • CROSS-LINKING

    We cross-link our hydrogels using an electron beam accelerator. Such linking is achieved by introducing a high energy field, created by accelerated electrons, which causes the release of hydrogen atoms and causes carbon molecule covalent bonding. The creation of longer chains of the polymer in the gel increases its molecular integrity, giving the gel characteristics that make it useful in a variety of products.

Do you have a question about our custom skin-friendly hydrogels? Don’t be shy, drop us a line and one of our team members will get back to you within 24 hours!