As advancements in medical coiling technologies continue, it’s crucial to have access to skilled micro coiling engineers, rapid custom design turnarounds, and high-quality products to stay ahead of the curve.
Micro-wire coils, used in a variety of medical components, are a growing trend in the industry. The wire used in these coils can be as small as 0.001 inches and are most often utilized in guidewires for interventional devices. Due to the intricate nature of the human vasculature system, these devices must be incredibly small, and micro coils play a critical role in treating specific areas within the body.
In some cases, micro coils are embedded within multiple components to provide radiopacity (opacity to X-rays), helping healthcare professionals visualize medical devices within the body. For patients, this means shorter hospital stays and reduced post-surgery risks, thanks to less invasive procedures. However, the process of manufacturing micro coils presents its own set of challenges, particularly due to their tiny size and the specialized equipment and expertise required for precision production.
The Techniques Behind Micro Coiling
Producing micro coils involves a variety of techniques, according to Jim Boldig, Director of Engineering at Custom Wire Technologies (CWT). “We have two methods which we use to produce micro coils. We can use our coil winding machines, or we can use our point coilers. Each method has its advantages and disadvantages.”
“However, our experience allows us to select the best method based on a variety of factors. Some of these factors include machine capacity, personnel scheduling, and tooling availability. Ultimately, CWT must consider what is best for the customer while working to achieve a production-ready program.”
CWT excels at developing custom prototypes that are FDA-approved and then scaling up production as the customer’s market grows.
When Is a Coil Considered ‘Micro’?
“Small is a relative term, but it is common in the medical device industry,” says Boldig.
“CWT considers a wire ‘micro’ when diameters are less than 0.076mm. We also consider the coil diameter as part of this classification. When the coil OD (outer diameter) is less than 0.50mm we consider it to be a micro coil. These wire and coil diameters require specific processing equipment to achieve this level of miniature size.”
Materials and Quality Control
Micro coils can be manufactured using various metals and alloys, such as stainless steel, nickel titanium, platinum, and tungsten.
“Of the materials we work with, not one is better suited than the other,” notes Boldig. “They all have their unique attributes and challenges. The question CWT asks of its potential customers is, what is needed for the particular device? CWT will determine the best method to manufacture the coil based on the customer’s needs.”
Working on such a tiny scale is no easy task. That’s why CWT employs a robust Quality Management System, ensuring every step of production is closely monitored. This includes well-documented inspection procedures and a rigorous preventative maintenance program.
“Our personnel are trained by factory technicians and receive further on-the-job assistance to ensure adherence to specifications,” Boldig continues. “All machine tooling is purchased direct from the factory to aid in the precise scale of these micro coils. While it may just be a machine manufacturing these coils, many processes have a significant impact on the end product.”
Experience & Innovation
With years of experience in micro coil manufacturing, CWT is uniquely positioned to deliver top-quality products. “Not all medical device companies can claim they have been producing micro coils since their inception,” says Boldig. “When CWT was founded in 2002, one of the first machines purchased was a machine which specialized in producing micro coils.”
CWT continues to innovate, recently launching its QwikCoil Program, which provides manufacturers with custom coils in just one week. This service is invaluable for companies needing quick turnarounds on their orders.
CWT has fine-tuned its techniques for manufacturing, inspecting, and even packaging micro coils. “Through years of manufacturing, CWT has learned what works and what doesn’t when it comes to working with these micro coils. We know the techniques to be effective at manufacturing, inspecting, and even special packaging of these types of products,” adds Boldig.
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If you’re interested in learning more about how Custom Wire Technologies can help you out, please reach out today. We’re excited to learn how we can serve you and help your business thrive!