The Challenge

An emerging medical device OEM approached Integer to help overcome critical challenges in developing a next-generation neurovascular catheter. Their conventional braiding and assembly processes couldn’t meet the stringent requirements for small-diameter shafts, precise pitch control, and distal flexibility. Manufacturing was constrained, performance varied, and development took longer than expected. To test a fresh strategy, the OEM required a partner with strong engineering knowledge, materials experience, and quick response times.

The Solution

Integer’s R&D Velocity engineering team collaborated closely with the customer to rapidly evaluate design concepts and build functional prototypes. Leveraging the company’s extensive materials knowledge, advanced process technologies, and internal multidisciplinary R&D infrastructure, the team designed for manufacturability from the very first iteration. Within eight working days, Integer produced working prototypes that demonstrated both performance and scalability potential.

Catheter Industry Problem:
Braid Wire Termination / Wire Spring Break

Laser Cut / Wire Termination Line

Central to the success was Integer’s proprietary braid annealing & termination process. This innovative technology eliminates the need for conventional braid transfer and manual termination, providing a highly repeatable and efficient method for processing micro-diameter shafts as small as 0.5 Fr.

Key technical benefits included:

• Precision and repeatability through direct wire annealing and termination on PTFE liners.
• Reduced handling by eliminating manual braid transfers and rework steps.
• Improved yields and minimized variation through automation and process control.
• Enhanced appearance and functional consistency, with clean braid terminations and reduced outer diameter growth.

The Results

In less than two weeks, the OEM received functional prototypes that not only met their design criteria but also validated manufacturability for future production. The rapid collaboration between Integer’s subject matter experts and the customer’s R&D engineers accelerated design validation and allowed immediate progression into the next development phase.

Integer’s R&D Velocity engineers integrated manufacturability early in the design cycle, resulting in measurable improvements in development speed, process efficiency, innovation and quality.

Key Takeaways

This project demonstrates how Integer’s engineering expertise and R&D Velocity ecosystem work together to help medical device companies move from concept to commercialization faster.

By uniting rapid prototyping capabilities, advanced processes, and deep manufacturing insight, Integer ensures that every prototype is built with production realities in mind. For this OEM, that meant faster proof-of-concept validation, reduced development risk, and a clear path to scalable manufacturing.

When innovation meets manufacturability from the start, great ideas reach patients sooner, and Integer’s R&D Velocity engineers make that possible.