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Medical device failures occur more often than we would like. Many times, these failures stem from material, design, or processing issues. During this presentation strategies for fielding robust medical products will be discussed through capabilities and case studies. Topics will include material selection, polymer welding (ultrasonic, laser, IR, spin, etc.), dissimilar material joining, modeling, and characterization. Case studies will be used to show novel applications for small parts, as thin as 0.003 inches, and continuous fiber filled thermoplastics. The audience will gain an understanding of new ways to join and assemble medical devices in a cost effective and reliable manner.