Resonetics PRIME Laser Cut™ offers medical device designers a new and fresh option for developing the latest life saving catheters and delivery systems. Laser cut tubing (LCT) has been used in medical device manufacturing for over 30 years with major advancements following the push for miniaturization for minimally invasive procedures. Laser cutting uses a focused laser to melt or ablate through one wall of a metal or polymer tube and remove the degraded material via a high-pressure coaxial gas nozzle.
In the past, for catheter delivery systems, this process has been too slow and costly to incorporate. However, Resonetics has combined advances in laser and motion control to develop a cost-effective tool for high-volume manufacturing of catheter components. This high-speed laser cutting process is branded as PRIME Laser Cut.
Laser cut spiral and interrupted spiral tubing offer several compelling advantages over traditional manufacturing processes:
Customization: A key benefit of laser cutting is the ability to completely customize the part geometry to match the clinical demands of the catheter. For example, if you are designing a catheter with significant stiffness on the proximal end but require uniaxial flexibility on the distal end, this can be difficult to achieve with a traditional braiding/coiling technique. With LCT, this custom flexibility can be incorporated easily into the laser cutting process.
Torque Transfer: Interrupted spiral cutting maintains a monolithic connection which enables flexibility but maintains a continuous link from proximal to distal ends of the catheter. This direct connection ensures a good torque response when advancing the device.
Kink Resistance: A monolithic construction optimizes kink resistance. As devices become more flexible, they have a higher risk of kinking upon insertion or advancement. A laser cut tube provides greater strength without compromising functionality.
Ovality: A challenge with braided/coiled delivery systems can be ovality or flattening when moving through tortuous anatomy. This is a significant issue when passing devices through the inner lumen of a device. A monolithic tubing design is less prone to flattening. Since LCT is monolithic, it does not collapse as it propagates tortuous anatomy. This is critical when passing additional devices through the inner diameter of the catheter.
Low Profile, Optimized ID: Thin wall tubing (down to <0.0005”) can be used with catheters to open up more space to pass larger devices through the inner lumen.
Simpler Design Reduces Labor: A laser cut tube eliminates the need for a tie layer and mandrel. Unlike braid, there are no loose ends to address.
Medical device designers have a new option to consider when developing the latest catheters and delivery systems. Utilizing advanced laser technology, Resonetics offers PRIME Laser Cut as a fresh alternative to catheter constructs made with metal braid and coils. Once cost-prohibitive, a monolithic tubing construct can be designed with unrivaled customization to create the performance profile needed for the latest advancements in minimally invasive procedures.
Sponsored content by Resonetics