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The Art of tube extrusion

Table of Contents

Intro

Zeus is a world leader in high-performance polymer solutions. Their focus is on precision extrusion of advanced polymers to create tubing and other components used in demanding, mission-critical applications.

The types of tubing they make are defined by the advanced materials they use and the specialized forms/structures of the tubing.

Materials

Zeus specializes in high-performance polymers, particularly Fluoropolymers and Engineered Plastics, known for their superior lubricity, temperature resistance, chemical resistance, and dielectric strength.

Polymer Family Key Materials Properties & Applications
Fluoropolymers "PTFE (Polytetrafluoroethylene, often called Teflon®), FEP, PFA, ETFE" "Highly non-stick (lubricious), high chemical and temperature resistance. Essential for catheters, electrical insulation, and critical fluid transfer."
Engineered Plastics "PEEK (Polyetheretherketone), PVDF, Nylons, LCP (Liquid Crystal Polymer)" "High mechanical strength, excellent wear resistance, and high column strength. Critical for structural components in medical devices and harsh industrial environments."
Biomaterials "Bioabsorbables (e.g., polymers used in Absorv®)" Materials that can safely exist in the body for a controlled time before dissolving—used in things like temporary stents or sutures.

Specialized Tubing Forms & Structures

The Letterkenny facility would likely manufacture these custom forms for customers in the medical, aerospace, and energy sectors:

Single Lumen Extruded Tubing

The most common type, manufactured to extremely tight tolerances (e.g., the proprietary Sub-Lite-Wall™ series, which can have very thin walls for catheter liners).

Multi-lumen Tubing

A single tube with multiple internal channels or "lumens" extruded within one outer diameter. Used to pass multiple wires, fluids, or fibers in devices like advanced catheters.

Heat Shrink Tubing

Used to insulate, protect, or bind components together, shrinking to fit when heat is applied.

Convoluted Tubing

Tubing with a corrugated, spiral design, offering high flexibility and excellent dielectric strength, often used in aerospace and automotive wire harnessing.

Aeos™ ePTFE Porous Tubing

Tubing made by expanding PTFE to create microscopic pores, making it highly flexible and useful for analytical lab testing or soft liners in endoscopes.

Special Profiles and Monofilament

Custom extruded shapes, not just round tubing, designed for specific mechanical or structural functions.

🔬 Quality Supervisor Questions (Technical & Situational)

These questions focus on your technical aptitude, attention to detail, adherence to standards, and ability to handle the core job responsibilities.

Attention to Detail & Inspection

Walk me through your process for performing a visual inspection

of a small, critical product. What steps would you take to ensure you don't miss any defects?

Describe a time when you identified a defect

or non-conformance that others might have missed. What did you do?

What do you understand by the term "critical to quality (CTQ)"

in a manufacturing environment?

Measurement & Analysis

What types of measuring tools

(e.g., calipers, micrometers, optical systems) are you proficient in using?

Explain how you would ensure your measurement readings are accurate

and repeatable.

The job requires measuring and recording variable data.

Describe your experience with data analysis and documentation to ensure product quality.

Quality Systems & Cleanroom

How familiar are you with Quality Management Systems

(like ISO standards)? (They may ask for specific standards if you mention prior experience, e.g., ISO 9001 or ISO 13485 for medical).

What challenges do you anticipate working in a cleanroom environment

with gowning controls, and how would you ensure compliance?

What is the importance of final inspection before shipment,

especially for products used in critical applications like medical devices or aerospace?

🤝 HR Questions (Behavioral & Cultural Fit)

HR will focus on your work ethic, reliability, teamwork, and cultural alignment with Zeus's values ("What we do matters" and "passion for customer quality").

Motivation & Commitment

Why are you interested in working specifically for Zeus

and our facility in Letterkenny?

The job involves either a day or evening shift.

Which do you prefer, and how do you manage consistency and energy levels during your chosen shift?

The products enhance and save lives.

How does knowing this influence your approach to quality and attention to detail?

Work Style & Reliability

Describe a time when you had to perform

a repetitive task for an extended period while maintaining high accuracy. How did you stay focused?

Tell me about a time you had to follow

a standard operating procedure (SOP) that you disagreed with. How did you handle the situation?

How do you respond to constructive criticism

regarding your work performance or quality?

Teamwork & Communication

Quality Inspectors must communicate effectively

with production and management. Describe a time you had to clearly communicate a serious quality issue to a different department.

How do you manage your time and prioritize tasks

when faced with a high volume of product needing inspection before a deadline?

🎯 Preparation Tips

Review the Zeus Products

Spend time on the Zeus website to understand the types of tubing they make (e.g., PTFE, PEEK, FEP) and their demanding applications. Show you appreciate the gravity of their work.

Use the STAR Method

For all behavioral questions (e.g., "Describe a time when…"), structure your answer using the Situation, Task, Action, Result format.

Prepare Your Questions

At the end, be ready to ask them questions. Good examples:

"What are the key challenges the Quality team

is currently focusing on?"

"What does the training process look like

for a new Quality Inspector?"

"How does the Quality department interact

with the Engineering or Production teams?"