4 Design Considerations for Precise Catheter Shaft Performance 

The Medical engineered shaft is a core function in the development of complex delivery systems.

The design and development of the shaft requires finding an exact balance of performance qualities per the functional requirements of the device application. 

Device shafts can be optimized for flexibility, kink resistance, torque and tracking. Braided shafts are the best solution for catheter designs requiring excellent torque control with little whip. And Coil Reinforced shafts offer kink resistance, superior hoop strength, and pushability. 

With a braid and coil combination you can significantly reduce wall thickness while achieving the optimal balance of torque and flexibility along the length of the shaft.

We recommend four actionable design considerations for achieving specific performance characteristics required from your catheter shaft.

Catheter Shaft Design Considerations

1. Increase Shaft Flexibility
   By implementing durometers on the exterior jacket length – Higher durometers will stiffen the shaft.

2. Increase Flexibility + Torque Response
   Use a 2-wire diamond pattern, full load for the braid design to increase flexibility and better torque response 

3. Control Flexibility and Kink Resistance
   By varying the pitch of the braid i.e. the number of times a wire crosses in a 1” length of the shaf you can desired levels of flexibility and kink resistance

4. Achieve Lower profiles with Higher Torque
   Use flat and round wire alternatives for your braid design. round wires will provide a more flexible shaft but will increase overall profile. Flat wires will provide lower profiles. It’s important to note that high torque levels will not allow the same flexibility.

Developing the optimal catheter shaft requires a strong understanding of the technologies and manufacturing capabilities involved to achieve the desired characteristics.

Quasar’s Catheter Shaft Operation

In December of 2021, Quasar Medical acquired the TE/Creganna operation in Singapore specializing in Braid & Coil Shaft Manufacturing, Catheter Assembly, and Braiding & Extrusion. 

Combining the capabilities from the TE/Creganna acquisition together with Quasar’s current standing as leader in sensor technology, Quasar Medical cements its position as the leading contract manufacturer in the attractive minimally invasive interventional segment of the medical device market. Quasar now has the most complete product and capability offering in the industry and is a fully integrated strategic supplier to major OEMs. 

“I am very excited to welcome the new capabilities that the Singapore team will bring to Quasar” said Alex Wallstein, CEO of Quasar Medical. “The addition of the Singapore operation strengthens Quasar Medical as one of the leading suppliers for the minimally-invasive interventional segment and broadens our value proposition to our customers. We look forward to investing and further growing capacity in Singapore.”

About Quasar Medical

Quasar is an end-to-end contract manufacturer with over thirty-three years of experience of commitment to quality.

Our core competency is in process development and workflow management, which results in higher efficiency while maintaining the highest quality levels. 

Quasar can give you a competitive advantage at either stage, supporting the design stages of a medical device.

We offer you cutting edge, innovative technologies for your minimally invasive devices that guarantee your competitive edge in the market.