Complex Micro-Assembly

Smaller devices for smarter, minimally invasive solutions

Micro Assembly

Since the 1990s, the world has witnessed major breakthroughs in minimally invasive interventional procedures. The medical devices used for these procedures are becoming smaller–ranging from a few microns to a few millimeters—more precise, and more functional. Incidentally, the smaller the medical device, the greater it’s level of precision. But micro-assembly is far more complex than fabricating macro-devices, due to adhesion, as well as electrostatic and Van der Waals forces.

Highly specialized equipment in 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- medical devices such as balloon catheters, guide wires, micro-electronic components, micro-pacemakers, electrode catheters, and much more are manufactured using micro-assembly.

The Micro-Assembly Challenge

Facilities hosting micro-assembly lines must be supported with specialized machinery and the required infrastructure: cleanrooms with HEPA filters designed in accordance with ISO 14644-1 and cGMP standards. Fully automated or semi-automated lines require large spaces, while proper maintenance of these specialized areas is critical for precision manufacturing. It is also mandatory that cleanroom personnel receive extensive training. And since micro-device order sizes can vary tremendously, the facility needs to be geared for volume variations as well.

Approach & Solutions

Quasar opens up new possibilities for miniaturized system solutions and creates innovative products without any limit on their size. We run the most advanced production lines, combining both human and automated processes, whether in manufacturing, AOI (automatic optical inspection), or packaging. Our micro-assembly lines can handle devices under 10 microns, with an automated adhesive-placement process for the production of any batch size. Quasar has also launched an automated machine vision and measurement process for quality control.

Micro Assembly
Advantages of Micro-Assembly
  • Planning, process engineering, and developmental expertise covering micro-3D product specifications
  • State-of-the-art automation processes at its core and across the manufacturing life cycle
  • Optimal product QC and QA
  • High efficiency and consistent output
  • Assembly of devices and components under 10 microns
Micro Assembly
<10 Micron Capability
Precision Planning
Precision Planning
High Quality
High Consistency
High Consistency
High Performance
High Performance

Our customers benefit greatly from our unique capabilities. As partners in the design process, we plan for and execute production with a fixed duration and high consistency.  We provide the highest level of performance to our clients: The 10,000th product manufactured is identical and of the same quality as the very first. This ultimately saves months of training and ensures operating at the highest efficiency.

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