Tie Layer

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Delamination is a challenging failure mode in catheter construction that carries both risk and cost burden for device manufacturers. Detection typically does not occur until final testing – after catheter assembly is complete – resulting in significant product loss. Zeus’ Tie Layer solution helps combat this issue by creating a bondable surface that improves jacket-to-liner adhesion.

Primarily designed for use during catheter construction, this ultra-thin thermoplastic layer is typically applied over a PTFE catheter liner before braid or coil reinforcement is added. During the jacket reflow process, this thin coating forms a strong, heat-welded bond with the overlying jacketing material. By creating a stronger bond between the outer catheter jacket and inner liner (20-40% improved bond strength1), Zeus’ Tie Layer solution helps improve consistency in catheter performance, reduce manufacturing costs, and increase product yield.

Multiple Options

Tie Layer can be applied to almost any round substrate. For catheter construction, products that can be manufactured with a Tie Layer include:

Available Tie Layer Materials Include:

  • Pebax® – 25D* – 72D
  • Vestamid® 75D (Nylon)
  • Tecoflex® 80A
  • Other materials available upon request

Coating thicknesses from 0.0001″ – 0.0003″ Ref. (0.0025 mm – 0.0076 mm Ref.).

Don’t see what you want?   Tell us what you need.   Additional materials and durometers are available upon request.

* Pebax® 25D and 35D feature an additive for easier handling.
1 Based on Test Report, Overcoming Catheter Failure with Tie Layer. October 2020.

  • APPLICATIONS

    Catheter Construction –Tie Layer coatings can be applied to bondable substrates such as etched PTFE liners to promote adhesion of the subsequent outer jacket materials during the reflow process of catheter construction. Tie Layer increases jacket-to-liner bond strength ranging from 20-40%1 with minimal to moderate liner stretching.

    Metallic Hypotubes – Additionally, Tie Layer coatings can be used in conjunction with an etched PTFE liner to line the ID of a metallic tube, such as a laser-cut hypotube, to create a very low-friction ID (lumen).

    Other – Tie Layer coatings can be applied to components that need improved bondability to overlying materials.

  • KEY PROPERTIES

    Biocompatibility – For medical applications, Tie Layer coatings use only USP Class VI approved thermoplastic materials.

    Heat Weldable – Tie Layer coatings easily melt to coincide with any jacket reflow process, creating a strong and heat-welded bond.