Intelligent Catheter Design and Processing
Conventional catheters have a limited range of motion and flexibility and rely heavily on the operator’s skill and experience to maneuver the tip of the catheter to reach the target site.
The main advantages of an steerable catheter are better access to difficult anatomical sites, improved stability of the catheter during the procedure, shorter fluoroscopy time, and a reduction in the total radiation exposure for both the patient and the physician. Achieving this level of performance requires careful consideration during early design stages, particularly when applying design for manufacturability principles to ensure scalability and consistency. Learn more about design for manufacturability
In addition to electrophysiological procedures, structural heart surgery, and peripheral vascular surgery, steerable catheter are being used in an increasing number of interventional procedures, including neurological interventions, renal artery ablation, oncological interventions, and even arthroscopy. As these applications expand, rapid prototyping plays a critical role in testing and refining catheter designs before moving into full production. Learn more about medical device prototyping
Steerable catheter not only need to control the bend accurately, but also need to have stable support, as well as very good resistance to bending and torsion control. Translating these complex design requirements into reliable production outcomes depends on a structured design transfer process. Explore medical device design transfer
As catheter technology evolves, many companies are turning to specialist partners to support complex design and manufacturing challenges across the full development lifecycle.
Learn more about what a medical device CDMO does
Solutions Offered at Salt Medical
Material Expertise: Salt’s technical team has extensive experience with materials including outer thermoplastics such as Nylon, Pebax, PU, etc. for controlled bending properties. We are able to offer the most suitable material options according to the customer’s needs. These material and process decisions must also be validated to ensure consistent performance, safety, and regulatory compliance. Read more about medical device design validation
Process Expertise: Salt’s technical team fully understands the impact of different processes on the performance of the catheter, and provides a complete set of metal processing (cutting, welding, punching, etc.), wire braiding and winding, catheter forming services, as well as non-welded controlled-bend wire multi-strand punching process. We are especially good at the design and cutting process of hypotube and the design and process of braiding, which can fully satisfy the performance requirements of the catheter such as bending resistance and torsion control.
Design Expertise: Salt’s technical team has experience in the design and development of several innovative catheter products around the world, starting from diverse clinical needs through innovative designs that are not limited to generic catheter material and process choices, including:
- Multi-sized steerable catheters from 2-33F with 45-360° bend control
- Individualised pull-wire fixation solutions are available, including soldering, multi-stranded wires, etc
- Interactive bending of metal tubing without the need for wires
- Clinical applications: electrophysiological (controlled bend guidance), peripheral (torsion sheath), RDN, etc
Reference: Steerable catheters for minimally invasive surgery: a review and future directions
About Salt Medical
Salt Medical is an international medical device CDMO company with an established global R&D and manufacturing network. We consist of R&D centers in Ireland and the U.S., and large-scale manufacturing centers in Asia Pacific. Focusing on catheters, guidewires, medical endoscopes, surgical robots and other product areas, Salt has accumulated a wealth of experience in the design, development and production of innovative products in cardio, neuro and endovascular applications as well as digestive, respiratory and other clinical areas. We utilise a fully synergistic network to provide the most cost-effective and responsive services to global medical device manufacturers.
Continuous improvement across design and manufacturing processes ensures that catheter performance continues to evolve alongside clinical demands. Explore continuous improvement in medical device manufacturing
Related Insights in Medical Device Design & Manufacturing
Explore more insights across catheter innovation, design, and medical device manufacturing:
Pulsed Field Ablation (PFA) Catheter Technology
What is a Medical Device CDMO and Why Do You Need One?
Design for Manufacturability in Medical Devices
Medical Device Prototyping: From Concept to Reality
Medical Device Design Transfer Explained
Medical Device Design Validation Explained
Continuous Improvement in Medical Device Manufacturing
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