“Can you suggest a medium-viscosity adhesive that is well suited for metal-to-metal bonding?”
“We are currently using Dymax 1184-M, M-B, and V for most applications. However, we’ve found out that they are not well suited for bonding metal to metal, partly because the cured hardness is too high and partly because the UV light cannot penetrate through metal seams.”
For metal-to-metal joints I would suggest looking at traditional epoxies rather than light-curable acrylates.
Epotec and Master Bond Inc. offer epoxies in medical-grade versions. There is an old article that describes the impact of Sterrad low-temperature hydrogen-peroxide-gas plasma on several adhesives. The article, along with the results, can be viewed at: http://www.mddionline.com/article/compatibility-medical-devices-and-materials-low-temperature-hydrogen-peroxide-gas-plasma.
According to the results in the article, some two-part epoxies from Epotec have a moderate compatibility with Sterrad.
"Hello, I am using DYMAX 140-M to bond ABS to stainless steel. The product will be sold sterile in a Tyvek and LDPE/PET laminate pouch. Is there any data that shows the adhesive will not interact with the packaging in a way that could compromise the sterile barrier as the product sits on the shelf?"
Unfortunately we do not have data as specific as this. With so many applications around the world, and with so many substrates and packaging options being used, we have not attempted to determine the effects of cured adhesive in contact with the device packaging. The medical adhesives are usually tested for contact with blood, skin, muscular implant, etc., per ISO 10993/USP Class VI procedures, all with good results. If the material is cured properly, then after cure it is considered a solid plastic (urethane/acrylic type). We do not use any type of plasticizers or migrating materials that could compromise the integrity of the sterile barrier.