TE Connectivity adds 3D printing for catheter shafts

TE Connectivity has introduced a new additive manufacturing process for the production of catheter shafts, developed by its Medical business unit in Galway, Ireland. This technology allows for the direct application of polymer jacket sections with varying flexibility onto catheter shafts, streamlining a traditionally complex manufacturing step. By integrating 3D printing into medical device production, the company aims to accelerate design iterations and enable more sophisticated, minimally invasive device architectures.

Developed by the Advanced Technology Group at the PROPELUS Prototype Center in Galway, Ireland, the new technology automates the application of polymer jacket sections onto catheter shafts. Catheters typically require multiple sections with different flexibility characteristics along their length; this process applies them directly during production rather than through traditional assembly. TE Connectivity reports that the resulting components maintain the same mechanical properties, materials, and aesthetics as those produced via traditional manufacturing methods while offering a more consistent and rapid output.

According to Pat Duane, senior vice president and general manager of TE’s Medical business, additive manufacturing is central to the company's focus on advancing manufacturing innovation for sophisticated medical devices. The process allows engineering teams to iterate designs more quickly, significantly reducing the time required for device development. Furthermore, it opens the door for manufacturers to explore new catheter constructions and device architectures that were previously considered impractical or impossible to create using conventional techniques.

Medical Engineering Fellow Bernard McDermott noted that this process, alongside other disruptive technologies currently in development, represents a paradigm shift for the industry. The adoption of 3D printing in this context is expected to significantly reduce product costs and simplify complex supply chains by streamlining the manufacturing workflow. Additionally, the transition to additive methods is projected to have a positive environmental impact, aligning with TE Connectivity’s broader goals as a global industrial technology leader.