Thermoplastic Extrusions
Over 30 extruders in a range of sizes up to 2 inches, (50.8 mm), 3D modeling and finite element analysis tool design, CNC and EDM tool manufacturing, and dedicated clean manufacturing space within our 37,000 square foot (3.5 square meters) facility allow our experienced staff to develop extrusions for challenging minimally invasive applications, scale processes and transition to manufacturing.
Our state-of-the-art manufacturing facility is ISO 13485:2003 and 9001:2008 certified, reaffirming our goal of maintaining a quality system of the highest possible standard. Fully equipped laboratory for incoming raw materials and on-line statistical process control as well as a vast array of contact and non-contact inspection technologies ensure that every product requirement is met.
Materials
Virtually all melt processed thermoplastic resins, including polyurethane, nylon, PEBAX*, PEEK, elastomers, polycarbonate, EVA, PVC, polyolefins, acetals, polyesters, fluoropolymers and more can be extruded in natural or compounded forms, with additives to affect color, radiopacity, lubricity, anti-microbial and other properties.
Configurations
We currently have the tooling and equipment necessary to produce extrusions with overall diameters in the range of 0.010” to 0.500”. In relatively thin walled applications requiring lower material output from the extruder, our largest 2” inch extruders are capable of producing tubing with overall diameters of just over 1.000”.
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Multi-lumen
Solid rods (beading) to complex multilumens provide working channels for the insertion of wires, or the transport of fluids or miniature devices. Available in diameters from 0.005” (0.127mm) to over 1.00” (25.4mm), from round to complex profile shapes inside and out.
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Co-Extrusion
Multiple materials in a single extrusion, from stripes to encapsulated profiles to four coaxial layers, are required for complex catheter shafts. These include catheters requiring a portion be radiopaque under fluoroscopy and a portion clear for visibility of the lumens; or a hard, lubricious inner surface and soft, bondable outer surface for use in guide wire catheters.
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Taper (Bump)
Extrusion cross sections can vary in size along their length. Such tapered extrusions are commonly used to create variable stiffness from proximal to distal or to ease connections at the proximal end. Inside diameters can remain constant, while the outside diameter changes along the end.
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TIE (Total Intermittent Extrusion)
A proprietary process capable of producing extrusions with variable durometers along their length is commonly used in catheter shafts to provide a soft tip or combination of flexibility and stiffness for insertion.
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Wire & Fiber Jacketing
Longitudinal wires or fibers incorporated into an extrusion cross section provide specific benefits, such as structural support or electrical data transmission. Continuous jacketing of thermoset polyimide lumen linings, wires, fiber optics, Kevlar* reinforcement, and more are available. Discrete jacketing of tapered guide wires (including pre-cut Nitinol** or stainless steel), laser cut and/or tapered hypotubes, micro-coils, are also available.
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Braid & Coil Reinforcement
Reinforcements applied to single lumen, profile and multi-lumen extrusions include coil to resist collapse and buckling, and braid to improve burst strength and torque transmission. Reinforcement materials include stainless steel, Nitinol, or high tensile polymer fibers.