On Balloon Assembly

Creating high-precision balloons and balloon catheters

On Balloon Assembly

The effectiveness of minimally invasive procedures (diagnostic and therapeutic) has influenced medical practice in cardiology, neurology, nephrology, and many other medical disciplines. Devices such as the balloon catheter can travel through minute blood vessels without disturbing their natural shape. It is widely used to deliver stents, open blockages, dilate blood vessels, and much more. The balloon set on the catheter is controlled by the physician and made to inflate at the clogged site. While the material chosen for catheters is crucial, the manufacturing process used to make them is equally critical to produce the highest-quality device. Balloon catheters provide an ideal platform for deploying flexible circuit combinations, which enables the development of novel techniques. The high-precision manufacturing process involves extrusion of the balloon material into the shape of a tube, the circumference of which can vary from a few microns to a couple of millimeters. This is followed by the balloon-forming process or blow molding.

The On Balloon Assembly Challenge

The raw materials, design, and manufacturing techniques are unique for the balloon and its use. Balloons can be non-compliant, semi-compliant, or compliant, with each type made from a different material. The contract manufacturer must pay careful attention to the performance characteristics of each type, as these influence the design and manufacturing technique implemented. These include the time required to inflate and deflate the balloon, the catheter’s tracking ability to advance through complex pathways, and the insertion profile.

Approach & Solutions

Quasar’s expert product engineers and materials specialists ensure that the manufacturing process consistently delivers the highest-quality products. We ensure that the right mix of parameters, such as the gear-pump setting, temperature profile, tooling specifications, geometric considerations, and degree of crystallization, is used. Specialized metal braiding techniques and patterns offer precise catheter torque manipulation. We provide cutting-edge materials, micro-assembly lines capable of handling diameters less than 10 microns, and embedded electronics capabilities to be used in conjunction with balloon catheters.

On Balloon Assembly
Advantages of On Balloon Assembly
  • Specialized Materials: Selection and appropriate use of raw materials including hydrophilic, radiopaque, pressure-determined, hardness-determined, etc.
  • Manufacturing Techniques: Specialized balloon-forming techniques achieve the desired shape or burst-pressure levels to ensure safe and efficient balloon operation.
  • Micro-Assembly: Balloon catheters have detailed moving parts with specialized functionality. Quasar operates micro-assembly lines, utilizing microscopes, machine vision, automation, and highly trained operators to perform detailed parts assembly.
  • Embedded Electronics: When required, electronics of varying designs can be manufactured and loaded onto balloon catheters.
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Specialized Materials
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Consistent Sourcing
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Embedded Electronics
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Manufacturing Techniques
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Low Costs

As Quasar takes capabilities includes immense care to adhere to in maintaining regulatory compliances and standards, which is why we also provide prototyping and pre-production testing that eliminates production issues at later stages. This result is higher overall cost savings for customers and a higher, more consistent quality of products delivered within shorter timelines. We deliver top-quality and reliable fabrication of detailed parts that perform exceptionally in the medical field.

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