As EP catheter designs become smaller, more complex, and more difficult to manufacture, traditional wire preparation methods are increasingly becoming a production bottleneck.
Many manufacturers still rely on manual stripping processes using blades, tweezers, abrasive methods, or highly operator-dependent techniques. While these methods may work during early-stage development, they often create major challenges when moving into validated production.
The result can be:
Laser wire stripping provides a more repeatable, validation-ready alternative designed for modern catheter manufacturing.
Download the whitepaper to learn how leading medical device manufacturers are improving quality, reducing production risk, and preparing for scalable automation with laser processing.
Inside the whitepaper, you’ll discover:
EP catheter manufacturing continues to evolve rapidly, particularly with the growth of pulsed field ablation (PFA), high-density mapping, and increasingly miniaturized catheter designs.
These devices often use ultra-fine wires, delicate insulation materials, and complex conductor constructions that are difficult to process consistently using mechanical methods.
Traditional stripping approaches can introduce:
Mechanical Stress
Physical contact from blades or abrasive processes can damage delicate conductors and compromise long-term reliability.
Operator Variation
Manual stripping quality often depends heavily on operator skill and experience, creating inconsistency between shifts and production sites.
Validation Challenges
Highly manual processes can make validation more difficult due to inconsistent outputs and limited process control.
Scalability Limitations
Processes that rely on microscopes, tweezers, and manual handling become increasingly difficult to scale efficiently as production volumes increase.
Laser processing helps address these challenges through programmable, non-contact material removal.
Laser Wire Solutions specializes in precision laser wire processing for medical device manufacturing applications including PFA catheters, EP catheters, neurovascular devices, CRM leads, guidewires, and micro-coax assemblies.
Unlike general-purpose laser manufacturers, our systems are developed specifically around the challenges of medical wire processing.
Successful laser processing is not just about the machine, it’s about developing a stable, repeatable process for the specific wire construction and material stack-up.
Our team works directly with manufacturers to develop application-specific processes designed around:
Medical manufacturers require more than just a working sample.
Laser Wire Solutions supports customers with process development, documentation, FAT/SAT support, and production-ready solutions designed for regulated manufacturing environments.
Laser Wire Solutions systems are used globally across medical device manufacturing applications where precision, repeatability, and conductor integrity are critical.