Wire Forming for Surgical Devices: Ensuring Precision and Reliability
Wire forming is a precision manufacturing method commonly used to produce components for surgical devices. This process involves bending wire to create complex shapes with precise tolerances, which can withstand repeated use and extreme operating conditions.
Specialized applications for wire forming include stents, guide wires, and orthopedic implants.
The correct material alloy is crucial for achieving quality and reliability in medical devices.
An experienced wire-forming vendor can help ensure the quality and reliability of the wire component, even in the most demanding operational conditions and extreme operating environments.
When selecting a wire-forming vendor, consider their experience and track record. A reputable vendor will have the knowledge and expertise to select your application’s correct material and manufacturing methods.
What is a Wire Form?
A wire form is a custom-fabricated component made from either straight lengths or coils of wire, used in various medical devices.
Wire forming is a process that involves the use of specialized tools to reshape the wire plastically and achieve the desired finished part geometry. This process requires an understanding of the wire material properties, including their alloy and temper, as well as the behavior of the wire during the process, such as springback and cross-sectional wire deformation.
Some advantages of exceptional bending quality include the following:
- Long-lasting form.
- No material damages.
- Many possibilities in the resulting elements.
- Take advantage of the qualities of metal in specific tools.
Expert wire forming requires experience in tooling design, material science, and the ability to account for the complexities involved in the process. Wire-forming experts must also have knowledge of the various wire materials used in medical device manufacturing, including stainless steel, nitinol, and tungsten, to name a few.
Wire forming services in industrial porpoises
Manufacturing wire for industrial purposes must rely on specialized machinery and the guidance of engineers prepared to care for each stage of the process. In addition, the machinery and methods used for steel wire forming or different metals must be appropriate for each material.
Wire-forming services have been improving along with the development of industrial activity and the discovery of new materials. For example, Nitinol wire has found medical applications where the main characteristic is the precision and shape memory. Let us take a closer look.
Wire Shapes
In the manufacturing of wire components, wire profiles play a critical role. While round wire profiles are widely available off-the-shelf, many specialized applications require wire profiles with non-circular cross-sections. These profiles can be square, rectangular, obround, D-shaped, chamfered edge, and more.
Producing these wire profiles requires specialized tooling and processes that can plastically deform the wire material to the desired shape. This deformation can be achieved through cold forming, roll forming, or extrusion.
Common Wire Alloys
An extensive range of wire raw material alloys and tempers is available, and the material selection is based on various criteria. These criteria include spring properties, corrosion resistance, high-temperature resistance, chemical resistance, electrical conductivity/resistance, biocompatibility, super elasticity, shape memory behavior, and radiopacity.
Here is a partial list of wire alloys:
- Wire/carbon steel alloys: High-carbon steel alloys are used for springs and other high-stress applications.
- Pre-plated wire: Wire plated with zinc, nickel, or tin for improved corrosion resistance or other properties.
- 302 Spring temper stainless steel: A standard alloy with good corrosion resistance and spring properties.
- 304/304 V Stainless steel: A widely used stainless steel alloy with good corrosion resistance and toughness.
- 316 Stainless steel: A stainless steel alloy with excellent corrosion resistance, particularly in harsh environments.
- 316LVM (Vacuum melt) Stainless steel: A medical-grade stainless steel alloy with good biocompatibility and corrosion resistance.
- 17-7 CH900 (Precipitation-hardened stainless steel alloy): A high-strength stainless steel alloy with good fatigue resistance.
- Nitinol (Nickel titanium alloy): A shape-memory alloy with unique properties like superelasticity.
- Titanium: A lightweight and strong metal with excellent corrosion resistance.
- Cobalt chromium-nickel alloys (Elgiloy®, Phynox®, Conichrome®): High-strength alloys with good corrosion and wear resistance.
- MP35N & cobalt-chromium alloys: High-performance alloys with excellent strength, corrosion resistance, and biocompatibility.
- Phos Bronze (aka bronze phosphorous): An alloy of copper, tin, and phosphorus with good corrosion resistance and electrical conductivity
- Beryllium copper: A copper alloy with high strength, electrical conductivity, and thermal conductivity.
- Copper, brass, & bronze alloys: Common alloys with good electrical conductivity and corrosion resistance.
- Aluminum alloys: Lightweight alloys with good strength and corrosion resistance.
- Precious metals (gold, silver, platinum): Metals used for their unique properties, such as biocompatibility or electrical conductivity.
- Molybdenum: A metal with high strength and good thermal conductivity.
- Tantalum: A corrosion-resistant metal often used in medical implants.
- Braided wire: Wire made by braiding multiple strands together for increased strength or flexibility.
- Fine wire: Thin wire with diameters ranging from micrometers to millimeters.
- Surgical & implant grade wire: Wire designed explicitly for use in medical devices, with high biocompatibility and corrosion resistance.
Wire Forming Equipment
To produce high-quality wire-form components, it is imperative to have the correct, modern, and up-to-date wire-forming equipment, including specialized systems such as wire-forming and wire-bending machines.
Seisa Medical's Custom Wire Forming and Value-Added Services for Medical Devices
Wire forming is a critical process that requires specialized equipment, tooling, and expertise to produce high-quality wire components with precise fit, finish, and performance. Seisa Medical’s engineers and wire-forming experts can guide and support your medical, surgical, or other custom wire-forming needs.
Wire forming is often the first step in a comprehensive manufacturing process, including several subsequent value-added operations. Seisa Medical offers a full range of value-added services to meet your wire-forming needs.
We provide custom wire components for medical devices, surgical tools, and other applications tailored to your specifications. Our commitment to excellence ensures your complete satisfaction, and we utilize cutting-edge technology and our extensive experience in MedTech and precision manufacturing to produce the highest-quality wire components.
Our expertise in developing wire components and assemblies for therapeutic tools and working with specialized metals sets us apart in the industry. We provide prototype and high-volume wire-forming solutions that meet your needs.
Contact Seisa Medical today to learn more about our wire-forming capabilities and how we can help you develop the best wire components for your medical devices.
Seisa Medical: Methods & Value-Added Services
Seisa Medical Wire offers a comprehensive range of wire forming, cutting, machining, and finishing services for medical device manufacturers. Our state-of-the-art equipment and experienced team enable us to provide the highest quality products to our customers.
Wire Forming:
- CNC Coil-Fed Wire Forming
- CNC Press Brake Wire Forming
- Spin Tool Forming
- Pneumatic Toggle Press Forming
- Manual Wire Forming (Arbor Press Forming, Kick Press Forming)
- Swaging & Flattening
- Crimping
- Chamfering & Filleting
- Four-Slide Forming
- Centerless Grinding
- Wire Skiving
- Wire Scarfing
Machining:
- Machining & Grinding (Holes / Slots, Threads, Flats, Points, Sharps, Knurling)
- Wire & Drill EDM Processing
- Laser Welding to Other Wire Forms, Tubular Components, Machined Components
- Spot / Resistance Welding
- Soldering / Brazing
- Laser Marking
- Pad Printing
- Epoxy Ink Application
Finishing:
- Micro abrasion Blasting
- Plating / Coating
- Passivation
- Electropolishing
Heat Treatment & Analysis:
- Shape Setting / Heat Setting
- Stamping
- Heat Treatment, Hardening, Annealing
- Assembly
- Spring Analysis Services
- Functional Testing (Load Testing, Compression, Tension, & Cyclical Force Testing)
Our expertise in developing wire components and assemblies for therapeutic tools and working with specialized metals sets us apart in the industry. We provide prototype and high-volume wire-forming solutions that meet your needs.
Contact Seisa Medical today to learn more about our wire-forming capabilities and how we can help you develop the best wire components for your medical devices.
Wire Forming FAQ
Q. What are the advantages of exceptional bending quality in wire forming for medical devices?
A. Exceptional bending quality in wire forming for medical devices offers several advantages, including long-lasting form, no material damage, and many possibilities in the resulting elements. An experienced wire-forming vendor can help ensure the quality and reliability of the wire component, even in the most demanding operational and extreme operating environments.
Q. What common wire alloys are used in wire forming for medical devices?
A. Common wire alloys used in wire forming for medical devices include stainless steel (302 Spring temper, 304/304 V, 316, and 316LVM), nitinol, titanium, cobalt chromium-nickel alloys (Elgiloy®, Phynox®, Conichrome®), and precious metals (gold, silver, platinum), among others.
Q. What specialized machinery and processes are required to manufacture medical device wire components?
A. Specialized machinery such as wire drawing, precision cutting, and laser welding machines are required to manufacture medical device wire components. Processes such as wire drawing, straightening, cutting, grinding, and polishing are also necessary for producing high-quality wire components. Additionally, stringent quality control measures are implemented to ensure that the wire components meet the standards required for use in medical devices.
Q. Why is the correct material alloy crucial for achieving quality and reliability in medical devices produced through wire forming?
A. The correct material alloy is crucial for achieving quality and reliability in medical devices produced through wire forming because it can affect the device’s biocompatibility, corrosion resistance, and mechanical properties. Using the wrong alloy can lead to devise failure, patient harm, and regulatory issues.
Q. What are some specialized applications for wire forming in the medical device industry?
A. Wire forming is widely used in the medical device industry for various specialized applications, including guide wires, springs, catheter components, stents, orthopedic implants, and surgical instruments. These wire-formed components are critical in providing better treatment options and improved patient outcomes.
Q. What factors should be considered when selecting a wire-forming vendor for medical devices?
A. When selecting a wire-forming vendor for medical devices, some factors that should be considered include:
- Experience and expertise in medical device wire forming.
- Quality control systems and certifications, such as ISO 13485
- Ability to produce wire components to required specifications and tolerances.
- Capacity to handle the necessary volume of production.
- Flexibility and responsiveness to meet changing requirements.
- Ability to work with a variety of materials and finishes.
- Regulatory compliance and understanding of industry standards and regulations.