What is Nitinol?
Nitinol is a remarkable alloy of Nickel (Ni) and Titanium (Ti) which stands out for its extraordinary properties, notably its super-elasticity, shape memory and biocompatibility.
Super-elasticity allows Nitinol to exhibit remarkable elasticity under stress, snapping back to its original shape when pressure is released.
The shape memory effect of Nitinol allows it to undergo deformation at a lower temperature, and then, when heated, return to its original shape. This makes Nitinol useful in various applications, including medical devices, actuators, sensors, and other engineering applications.
Nitinol's biocompatibility, along with its shape memory properties and other beneficial characteristics, makes it a suitable material for medical applications like nitinol stents for blood vessels, guidewires, and other implantable devices. The ability to collapse for insertion through a catheter and then expand to the desired shape once inside the body makes it valuable for minimally invasive procedures.
The Significance of Nitinol Laser Processing
1. Ultrafast Femtosecond Laser Systems
Nitinol laser processing involves the utilization of ultrafast femtosecond laser systems. These laser systems emits ultra-short pulses in the femtosecond range which is one quadrillionth of a second (10^-15 seconds). This technology enables the laser cutting of Nitinol devices, reducing the need for extensive post-processing.
The ultra-short pulses produced by femtosecond lasers have unique properties such as high precision in material processing and high control over the interaction with materials as well as minimal heat transfer to the surrounding material.
The precision of laser cutting is paramount in the development of innovative medical devices and ensures that they meet critical performance requirements. AMETEK EMC understands the intricate relationship between laser processing and Nitinol's raw material properties. Expertise that has been used to design and build in-house laser systems. This capability enables AMETEK EMC to tackle the most complex Nitinol manufacturing challenges.
Flat Nitinol components laser cut, finished and assembled.
2. Advantages of Nitinol Laser Processing
Nitinol laser processing, involving the use of lasers for cutting, welding, or shaping Nitinol alloy, offers several advantages, especially in the medical device industry.
A)
Precision: Laser processing provides high precision and accuracy in shaping Nitinol components. The focused and controlled laser beam allows for intricate cuts and fine details, making it suitable for manufacturing complex medical devices
B)
Minimal Thermal Damage: Nitinol has shape memory properties, and excessive heat can alter these properties. Laser processing of Nitinol minimizes thermal damage due to the localized and controlled nature of the laser beam. This is crucial in maintaining the alloy's unique properties during manufacturing.
C)
Non-Contact Processing: Laser processing is a non-contact method, which means there is no physical tool touching the material. This eliminates the risk of contamination and reduces wear and tear on tools, leading to cleaner and more precise results.
D)
Versatility: Laser processing is versatile and can be used for various applications such as cutting, welding, and marking. This flexibility allows manufacturers to use a single system for multiple tasks, streamlining the production process.
E)
Speed and Efficiency: Laser processing is often faster compared to traditional methods, leading to increased efficiency in manufacturing. This is particularly important in industries like medical device manufacturing, where precision and speed are critical.
F)
Reduced Post-Processing: Laser-cut Nitinol components often require minimal post-processing. The precision of laser cutting reduces the need for additional finishing steps, saving time and resources in the production process
I)
Cost-Effective for Prototyping: Laser processing is well-suited for prototyping and small-scale production runs. Its ability to quickly and accurately produce prototypes can be cost-effective for iterative design processes in the development of Nitinol-based medical devices.
J)
Automation Integration: Laser processing systems can be easily integrated into automated manufacturing processes, allowing for high-throughput production with consistent quality. This is advantageous for industries with high-volume manufacturing requirements.
K)
Customization: Laser processing allows for easy customization of Nitinol components, facilitating the production of patient-specific medical devices. This is particularly important in the medical field where personalized treatments are becoming more common.
Overall, Nitinol laser processing provides a combination of precision, efficiency, and versatility that is well-suited for the manufacturing requirements of Nitinol-based components, particularly in the medical industry.
As laser cut sample with Nitinol self-expanding stent as laser-cut Nitinol stent implant.
Advancing Treatment Options
Innovators in medical device development turn to Nitinol laser-cutting capabilities to create groundbreaking technologies. Nitinol's properties, coupled with precise laser processing, contribute to the advancement of treatment options, ultimately improving patient lives.
Closeup of electro-polished Nitinol stent
Nitinol in Medical Device Applications
Nitinol laser processing plays a pivotal role in various medical applications:
- Stents: Nitinol is commonly used in the production of self-expanding stents for cardiovascular applications. Stents are implanted devices used to open and support narrowed arteries or other tubular structures.
- Guidewires: Nitinol's flexibility, shape memory, and superelasticity make it an ideal material for guidewires used in minimally invasive procedures. These guidewires can navigate through tortuous blood vessels and then return to their original shape after passing through tight spaces.
- Orthopedic Devices: Nitinol is used in orthopedic applications, such as bone anchors and intramedullary nails. These devices can be inserted in a deformed state and then return to their original shape once in position, providing stability and support.
- Dental Archwires: In dentistry, Nitinol is employed in the production of archwires used in orthodontic treatments. These archwires exert a constant force on teeth to move them into the desired position.
- Neurovascular Devices: Nitinol is used in the manufacturing of devices for neurovascular interventions, such as embolic coils for treating aneurysms. The superelasticity of Nitinol allows these coils to be easily delivered through catheters and then expand to fill the aneurysm.
- Urological Devices:Nitinol is utilized in urology for the production of ureteral stents, stone retrieval baskets, and other devices used in minimally invasive procedures within the urinary tract.
- Endoscopic Devices:Nitinol is employed in the construction of endoscopic devices, including retrieval baskets and snares used for removing foreign bodies or excising tissue during endoscopic procedures.
- Drug Delivery Systems: Nitinol can be integrated into drug delivery systems, where its shape memory properties allow for controlled release of medications over time. This is particularly useful in localized treatments.
- Robotics in Surgery: Nitinol components are used in the development of robotic surgical instruments due to their flexibility and ability to return to a predefined shape, enabling precise and controlled movements.
- Vascular Closure Devices: Nitinol-based closure devices are used to seal puncture sites in blood vessels after catheterization procedures, reducing the risk of bleeding.
The unique properties of Nitinol make it a valuable material in the medical field, enabling the design of devices that are both minimally invasive and highly effective in various clinical applications.
Laser cut, shape set and micro-blasted Nitinol processing example
Laserage – Decades of Expertise in Laser Machining for Medical Devices
AMETEK EMC’s expert brand Laserage has been at the forefront of Nitinol laser processing for implantable medical devices for more than 40 years. As companies move towards volume production, Laserage offers a comprehensive menu of Process Validation options to meet FDA requirements. Laser-machined Nitinol, along with other materials like stainless alloys, titanium alloys, cobalt chrome alloys, magnesium, and bioabsorbable plastics, are all cut with state-of-the-art laser systems.
Nitinol laser processing, especially in the hands of an experienced laser machining brand Laserage, is transforming the landscape of medical device manufacturing. The marriage of Nitinol's unique properties with precise laser cutting opens new possibilities for innovation, making medical treatments more effective and patient friendly.