Laser Cutting of Metal Tubes for Medtech—A Medtech Makers Q&A

By Sean Fenske, Editor-in-Chief

Surgery is constantly changing, with new preferences on techniques or the introduction of new technologies that cause a need to adjust a procedure. Recent trends have surgeries becoming less invasive and are even being assisted by robots, both of which offer advantages to both the physician and their patients. Medical device manufacturers have heard this call and continue to introduce new innovations to aid in this trend.

Fortunately, the device manufacturers’ suppliers have also continued to develop at the component level, refining how critical parts are developed and fabricated. One area that’s important for these surgical innovations are laser-cut tubes. These components must be precision engineered and meet tight tolerances. Lasers help ensure the necessary level of accuracy.

To help expand on why laser cutting of metal tubes is important and what considerations need to be kept in mind, Redi Nasto, Laser Technologies Manager at AVNA, responded to several questions. In the following Q&A, he provides insights on where laser-cut tubes are being used, commonly used secondary processes, and what to consider when specifying these parts.

Sean Fenske: When it comes to metal tube cutting, what methods are used? What advantages does laser cutting provide?

Redi Nasto: A variety of methods can be used for metal tube cutting, including Swiss machining and wire EDM. Stamp and roll or pierce methods are also options.

The primary advantages of laser cutting include substantial reduction of cycle times and the ability to process extremely small, intricate features and parts otherwise impossible with other methods. Additionally, minimal tooling and perishable requirements reduce costs and overall turnaround time, resulting in highly capable processes that ensure consistent, high-quality results.

Fenske: What are the medical device applications for metal tubing that have been laser cut? Where is it being used?

Nasto: The medical device applications for metal tubing are quite vast, from traditional and minimally invasive to robotic-assisted surgical devices. Metal tubing, provided in a variety of forms and sizes, can be used for almost any type of medical application, including tissue manipulation, cutting/piercing/dissection, grasping and handling, suturing, stapling and sealing, sensing, monitoring, visualization, and guidance and control, as well as implantables.

Fenske: Are there secondary processes available that further enhance the result following laser cutting? What are they and what benefits do they provide?

Nasto: There are a multitude of secondary processes available to enhance laser cutting, including bead blasting or tumbling, ultrasonic washing and cleaning (standard benchtops or vacuum cleaning systems), passivation, and electropolishing. AVNA offers these services internally and can incorporate them into the manufacturing process based on needs and requirements for specific products.

Fenske: What are the important considerations when specifying laser-cut tubing?

Nasto: Some of the important considerations when specifying laser-cut tubing start with raw materials. AVNA has established 15+ year trusted partnerships with key production material suppliers. During this time, we’ve produced tubing components and sub-assemblies from superior quality tubing.

Other important specifications include the tube outside diameter, inner diameter, and wall thickness ratios; on-axis versus off-axis cut features; and the total number of laser-cut features. These can dictate what type of laser source, laser cutting platform, and laser process settings would be required to optimize the results.

Next, a thorough review, understanding, and optimization of the customer blueprint drawings should take place. At AVNA, we have a long history of early involvement and collaboration with our customers, providing Design for Manufacturability input that optimizes the part function cost savings. While our customers design the parts, we develop and tailor the technology, systems, and processes required to take prototype concepts to high volume production. Our best customers are those who are open to collaborating with our process experts in an effort to develop innovative manufacturing solutions for complex medical device components and assemblies that ultimately improve and save lives around the world.

Fenske: What do you find surprises customers most about laser-cut tubing? Cost? Turnaround time? Something else?

Nasto: What usually surprises customers about laser-cut tubing is the attainable throughput and process speeds, ability to design intricate cuts and features, and the high level of accuracy and precision. Additionally, they are often surprised it is a non-contact process where a focused beam of light is used to cut through metal, resulting in minimal perishables.

Fenske: What other laser-based capabilities are available? Can you speak to laser marking and/or welding?

Nasto: Other laser-based capabilities that are core specialties at AVNA include: laser welding (structural and micro welding), laser marking (standard and ultrafast), and laser surface treatments (rounding, knurling, scribing, polishing, overmold retention features, etc.). We have more than 60 laser systems operational across three facilities as well as dedicated equipment and resources through our NexTech Labs that offer our customers the ability to collaborate on different projects. With dedicated resources for R&D, new product development/introduction, and sustaining, as well as with vertically integrated processes such as CNC/Swiss machining, stamping and metal forming, grinding, plastic molding, and a variety of parts finishing options, we offer full contract manufacturing services and solutions to the medtech industry.

Fenske: Do you have any additional comments you’d like to share based on any of the topics we discussed or something you’d like to tell medical device manufacturers?

Nasto: I would also like to mention that last year, we released our own proprietary next-generation laser tube cutting platform line, which is now available to produce high-volume production parts for medtech customers. Developed in-house by AVNA’s laser processing and automation experts, based on data and lessons learned from tens of thousands of hours of R&D and high-volume production experience, we have created a platform that utilizes some of the best components and latest technology available. This system incorporates a multitude of process controls that monitor, prevent, and detect potential process variation in real time. Complemented by a cross-functional and well-versed talented team of process experts, AVNA offers robust manufacturing solutions upon which medtech customers can rely.

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