Laser cutting
Laser cutting is a key technology that enables the manufacturing of miniature components at micron tolerances, particularly stents and surgical tools. STI uses the high-energy pulses of Nd:YAG and Fiber lasers to accurately cut intricate product designs from tubular and flat materials. STI's experienced laser cutting technicians maintain a fast and tension-free cutting process working with state-of-the-art laser cutting machines, capable of both dry and wet laser cutting, combined with CNC motion systems. CAD/CAM software directs the appropriate 2, 3 or 4-axes laser cutting process.
Micron level medical device specifications necessitate consistent, repeatable and ultra-precise laser cutting process. STI integrates hardware with software to optimize its laser cutting process per each product and material used by controlling diverse technological parameters, such as: Temperature stability, laser beam quality, cutting width (kerf), gas type, gas flow and pressure, motion control, controlled beam focus, beam angle, etc.
The cutting speed is determined by the raw material, the thickness of the sheet or tube, the complexity of the design, the kerf size, and the protective gas used. The wealth of experience acquired by STI over 12 years of medical device manufacturing of stents, heart valve frames, orthopedic devices and surgical tools, translates into excellent product quality, cost-effective solutions for clients and quick turnaround.
Advantages of high-intensity, pulsed, laser cutting
Complex 3D shapes
- Maintaining tight tolerance, micron level precision, while accurately cutting complex geometric contours of different thickness.
- Cutting a smooth and un-oxidized edge with little dross reduces finishing steps thereby improving overall production throughput.
- High peak power vaporizes part of the material while gas pressure pushes liquefied material out, resulting in minimal heat affected zone (HAZ) and thermal damage, e.g.: burrs, slag, and recast.
- Precise control over heat input by adjusting the beam diameter (cutting width) and pulse parameters (voltage, pulse width, frequency).
0.5mm ceramic film 19.42 μm holes
Laser drilling
STI uses Nd:YAG laser drilling technology to drill small size holes with a minimal diameter of 20 microns (0.0008") and positional tolerance of ± 0.005 mm in metallic and ceramic materials.
The ability to control the peak power and temporal profile of individual pulses, coupled with focus and angle adjustment of the laser beam, determine the diameter and shape of the hole.
Laser drilling has distinct advantages for laser machining including: drilling in difficult to reach areas, fast production rates, no tool wear, and drilling a wide variety of hole sizes, shapes and angles.
Laser sheet cutting
Laser cutting air cushion plate
Laser sheet cutting involves passing the laser beam over a flat surface. The laser beam vaporizes the material and the gas pressure applied through the nozzle pushes melting material out. The path of the laser beam over the surface determines the cutting pattern.
Typical applications for laser sheet cutting are miniature scalpels for eye surgery, plates, filters, optic masks, discs, rings, miniature cog wheels, vacuum nozzles, etc.
STI developed special laser cutting techniques for cutting thin metal foils and very fine shims or spacers of 0.005-0.05 mm thickness used for electro-optic calibration. These techniques enable STI to handle and laser cut thin foils without deforming their shape and without thermally affecting them.
Laser tube cutting
Laser cutting - stent manufacturing
STI uses both Fiber and Nd:YAG laser systems for cutting complete intricate shapes out of tubes. The 15 micron cutting kerf of the fiber laser is mainly used for cutting neurovascular stents made of Nitinol where the tube OD starts from 0.5mm. Stent cutting and heart valve frame laser machining require both rotary control and linear motion control. In special cases, STI uses its 4-axes laser cutting capabilities for cutting complex geometries of medical devices and non-medical applications.
STI applies laser tube cutting technology for medical device manufacturing of: balloon expandable and self-expanding stents, heart valve frames, orthopedic implants, guidewires, catheters, hypotubes, cannulae, needles, endoscopic and arthroscopic surgical tools.
Materials
STI processes a wide variety of materials, including: Stainless Steels (most common 316LVM), Brass (CuZn), Nickel Titanium (NiTi), Titanium (Ti), Aluminum (Al), Cobalt Chromium (CoCr L605, MP35N, Bio-Dur108, Phynox), Copper (Cu), Magnesium (Mg), Tantalum (Ta), Niobium (Nb), Tungsten (W), Aluminum Oxide (Al2O3 Ceramics), Gold (Au), Platinum (Pt) and Iridium (Ir).