Key Manufacturing Competencies
Leads design and manufacturing
The delicate wires connecting a device to its target anatomy are critical to the safety and reliable performance of your product. Cirtec’s seamless materials, design and manufacturing expertise helps to ensure even high-density leads will not succumb to fatigue or poor insulation and sealing. We can even help you explore novel architectures such as leadless (i.e. wireless) pacing.
Hermetic welding and testing
Hermetically sealing electronics against body fluids is critical to the safety and reliability of your implantable medical device. Combining glove box technology, vacuum ovens, advanced materials science and decades of engineering expertise, Cirtec is today a leading fabricator of hermetically sealed implantable medical devices. Yet no seal remains hermetic forever. So, Cirtec further provides unique expertise in testing hermetic leak rates. With our help, you can target and ensure an optimized leak rate for even the most compact device architectures.
Micro machining and manufacturing
The medical device industry has been making medical device assemblies with micron dimensions for some time, but in the last few years the miniaturization of medical components and assemblies has expanded. To accommodate these requirements, we have developed miniaturized capabilities to support all micron requirements.
- Micromachining – features under 10 microns – holes down to 40 microns
- Micro welding spot size to .0007″Ø
- Micro coil winding – .0005″Ø wire
- Micro EDM plunge to .001″, wire to .002″
- Micro insert molding
- Micro assembly
Standard and custom wire coil winding over mandrel or deflection winding are available in a wide range of wire coiling styles and sizes. We can supply all standard and custom materials including flat and shaped wire for coiled products. Our custom designed equipment allows us to manufacture with tight pitch control on straight, tapered or multi-pitched coils in all wire forms. All wire coilings for medical components and assemblies are manufactured in a Class 100,000 clean room for pristine wire coils. We have the ability to make medical device wire coils to the tightest tolerances required for the most stringent medical applications. Our tooling expertise allows us to consistently develop new methods to meet or exceed our customers’ tolerance requirements. We take extreme pride in our innovative abilities to create tooling and fixtures to support our proprietary wire coiling efforts. Wire coiling capabilities include:
- Outside coil diameter ranges from .002″ – .200″
- Inside coil diameters as small as .001″
- Overall lengths to 80“
- Tolerances to ±.0002″ on diameters
Laser welding and cutting
Laser welding provides accurate, repeatable and reliable joining for medical devices and assemblies. Components are laser welded using a fixtured and automated system. Spot size achievable as small as .0007″ diameter with automated circumferential weld. Laser welding provides precision joining of coil wires and joining of metal components for finished assemblies and is a proven method for joining a wide variety of metals and metal alloys.
Laser cutting produces close tolerance, tubular medical components devices and assemblies. Stellar Technologies’ system allows us to manufacture very complex, difficult components with an extremely accurate automated system. Our laser cutting process provides fast, flexible and cost-effective cutting of metals and non-metals.
Silicone molding, backfilling and adhesion
Both epoxy- and silicone-based polymers are instrumental to sealing and protecting sensitive electronics within active implantable devices fabricated under the ISO 10993 biocompatibility standard. However, both polymers have their benefits and drawbacks. Cirtec Medical’s expertise in the material science and implementation of either chemistry can help you determine which will best serve your device, and how best to apply it.
In-house EO sterilization
While required for many medical devices, sterilization by ethylene oxide (EO) can significantly extend product medical device lead times if products are transported off-site. Starting in 2016, Cirtec will offer onsite EO test cycles and validation services to help you accelerate your time to market.