Over the past three decades, the world has witnessed major breakthroughs in minimally invasive interventional procedures. Medical devices used for these procedures have had to become smaller ranging from a few microns to a few millimeters. Increasing demands are placed on their level of precision and functionality. Incidentally, the smaller the medical device, the greater the level of precision. However, manufacturing micro-devices is not the same as that of macro-devices. Material properties, electrostatic forces and micro-scale assembly all augment the difficulty of manufacturing
Highly specialized equipment as part of a fully-automated or semi-automated system is vital to successful micro-assembly. Micro-molding and micro-machining are complementary techniques used with micro-assembly. Micro Devices such as balloon catheters, guide wires, micro-electronic components, micro-pacemakers, electrode tip catheters, and much more are manufactured using micro-assembly.
Facilities that host micro-assembly lines must be supported with specialized machinery and the required infrastructure: Cleanrooms with HEPA filters designed as per ISO 14644-1 and cGMP standards. Large spaces are required for fully automated or semi-automated lines. Maintenance of these specialized areas is critical for quality manufacturing. Extensive training of personnel working within cleanrooms is also mandatory. Since micro-device order sizes can vary tremendously the facility needs to be geared for volume variations.
Quasar opens up new possibilities for miniaturized system solutions and creates innovative products without dimensional limitations. We run advanced production lines that combine both human and automated processes, whether in manufacturing, AOI (Automatic Optical Inspection), or in the packaging stages. Quasar can handle assembly of under 10 microns, with an automated adhesive placement process, for the production of any batch size. Quasar operates in-house automated machine vision and measurement processes for unmatched quality control.
Our customers benefit hugely from our unique capabilities. As partners in the design process, we plan for and execute production with fixed duration and high consistency. The 10,000th product that emerges is identical to and has the same quality as the first product, allowing us to provide the highest levels of performance to our clients, ultimately saving on months of training and operating at the highest efficiency.