When your device includes sharps, serrated components, or delicate features, a packaging failure can start with the smallest oversight, like an unprotected tip, edge, or point. At Eagle Medical, we engineer and integrate protective barrier components that prevent punctures, abrasion, or internal packaging damage before it starts.
Whether you need an off-the-shelf solution or a fully custom-designed barrier, we’ll help you build protection directly into your packaging system, without disrupting your sterilization or assembly workflows.
Eagle Medical supports a wide range of protective barrier formats, including:
Caps and plugs for tips, ports, and delicate connection points
Sheaths and sleeves for elongated or bladed elements
Protective wraps for fragile or surface-sensitive areas
Clamshells, custom enclosures, or rigid guards for high-risk components
Sterile secondary/tertiary bags for layered protection
Vial and ampule packaging for liquids or multi-part systems
Unprotected points and sharp edges can rupture pouches, deform trays, or compromise sterile barriers, especially during transit, sterilization, or handling. Eagle Medical designs barriers that account for:
Puncture and abrasion resistance during sterilization, shipping, or clinical use
Device geometry and tolerance mapping for barrier fit and retention
Moisture or chemical compatibility with surrounding packaging materials
Sterilization compatibility (VH₂O₂, EtO, gamma, etc.)
Ease of removal in the field for safe, intuitive surgical presentation
Because we work across design, packaging, and sterilization under one roof, we ensure protective barriers work within the system, not against it.
Protective barriers are not an afterthought. They’re a critical detail in your packaging validation pathway. Eagle Medical integrates barrier design into your broader packaging plan, including:
Tray, pouch, or kit layout mapping
Component nesting and stabilization
Validation testing support (ASTM D4169, F1929, and more)
Device-specific documentation for regulatory submissions
Ease of removal in the field for safe, intuitive surgical presentation
A single point of failure, like a serrated tip that wears through a pouch in transit, can derail an entire lot. Eagle’s approach to barrier integration ensures every element of your packaging works together to protect your device, meet compliance requirements, and perform reliably in the field.
Let’s close any gaps before they become problems.