A global leader in RF ablation and cardiac mapping catheters for treating cardiac arrhythmia transitioned from abrasive cone wire strippers to laser-based stripping. This move eliminated hidden sources of scrap caused by poor weld quality and removed operator dependency. By investing $130,000 per laser system, deployed across 80+ lines, they reduced scrap by 1.5%, equating to over $500,000 per line annually. Laser stripping is now their standard—and it’s changing industry expectations.
The Customer
A top-tier medical OEM manufacturing RF ablation and mapping catheters. Production runs 24/7/365 with over 80 manufacturing lines. High throughput, high value: 250 parts per line per day, each with a material value of $150 at the weld stage.
The Challenge
The customer had relied on abrasive cone strippers to prepare wires for resistance ring welding. However, the process was highly dependent on operator technique:
- Poor wire rotation led to incomplete stripping
- Overexposure weakened the conductor
- Residue and surface damage compromised weld integrity
- Worn wheels introduced uncontrolled variation
Resistance welds are sensitive to even minor imperfections. When they fail, the issue often isn’t correctly traced—it’s logged generically as an “electrical fault.”
This led to a 1.5% scrap rate. At scale, that’s $513,000 in wasted material per line, annually.
The Solution
The company replaced cone strippers with laser wire strippers—one per line over a five-year rollout. Each system represented a $130,000 investment, plus a few months for validation.
Our team supported the transition with:
- Sample characterization data
- Weld quality analysis
- Process recommendations for validation
The result was a consistent, contact-free strip with no operator variability. The process eliminated surface damage and ensured optimal weld readiness.
The Results
- 1.5% absolute scrap reduction, line by line
- Significantly improved weld quality and reliability
- Eliminated operator skill as a variable in the process
- Faster troubleshooting due to fewer false “electrical” faults
“Before lasers, a good strip was all about the operator. Now, we get perfect prep every time.”
— Senior Process Technician
“It’s one of the most cost-effective investments we’ve made. Scrap went down, confidence went up.”
— Manufacturing Manager
“We used to spend days chasing phantom electrical faults. Laser stripping helped us trace, fix, and prevent them.”
— Quality Engineer
Why It Matters to You
If you’re still using abrasive wire stripping:
- Your welds are vulnerable
- Your scrap might be hiding in plain sight
- Your operators carry the burden of precision
Laser stripping removes those risks. It’s fast, repeatable, clean, and proven by industry leaders.
Let’s Talk
Want to see how laser stripping can improve your yield and weld reliability?
- Request a free sample analysis
- Book a consultation with one of our application experts
- See a live demo or success webinar
Contact us at: sales@laserwiresolutions.com
Or call: +44 +44 144 384 1738
