Forming And Support Mandrels
Catheter construction begins with a solid core or mandrel upon which the catheter is built. Used to create or form the inside diameter (ID) during production, mandrels must provide consistent IDs and a smooth inner surface (lumen) for the finished catheter. Thus, choosing the right material with the right production process is crucial.
PTFE Monofilament
PTFE monofilament is a primary foundational component used for mandrels in catheter construction. PTFE’s naturally smooth non-stick surface helps facilitate mandrel removal after the construction of the finished catheter.
Glass-Filled PTFE Monofilament
For designs requiring a higher PIC count braiding, mandrels need to be capable of tolerating the additional compressive forces caused by the braid. Glass particles can be compounded with PTFE resin prior to extrusion to enhance the mechanical properties of the extruded PTFE monofilament (or thick-walled tube). Known for its high performing material properties, PTFE and Glass-Filled PTFE monofilament mandrels provide:
- High Lubricity For Easy Removal
- High Operating Temperature [500 °F (260 °C)] for Hot Lamination Environments
- Easily Drawn Due to Much Lower Load at Yield vs. PTFE-Coated Stainless Steel
| PTFE MONOFILAMENTS – TYPICAL CAPABILITIES | ||||
| TYPE | OD RANGE | OD TOLERANCE | LUBRICITY | STIFFNESS |
| PTFE | 0.004″ – 0.170″ (0.102 mm – 4.318 mm) |
± 0.0005″ – 0.003″ (± 0.0127 mm – 0.076 mm) |
★★★★★ | ★★★☆☆ |
| Glass-Filled PTFE | 0.006″ – 0.099″ (0.152 mm –2.515 mm) |
± 0.0005″ – 0.003″ (± 0.0127 mm – 0.076 mm) |
★★★★★ | ★★★★★ |
Tight Tolerances and Customization
Tolerances are king in catheter manufacturing, and Zeus remains a world leader in precision components with the ability to extrude PTFE monofilament mandrels down to ± 0.0005” (0.0127 mm) tolerances routinely on most sizes. Zeus PTFE mandrels may be available with various secondary operations including tip forming and tapering.