Bonds & Welds

Today’s catheter delivery systems rely on increasingly complex shapes, constructions and polymers to deliver their intended treatment.  Increasing complexity in catheter bonding and welding applications can only be consistently achieved through advanced technology and proper application of sound engineering principles.

Vante and PlasticWeld Systems equipment is the global standards for bonding and welding equipment.  Superior heating technology, proprietary thermal profiling and a defined customer engagement process lead by our experienced engineers – assure you get the best results possible.

Advantages of partnering with Vante and PlasticWeld Systems for catheter bonding and welding include:

  • Wide range of technology options and experience to match the customer requirements with the optimal solution and price point.
  • Turnkey solutions which will allow you to make parts and validate your process fast!
  • Robust equipment that is proven in high volume environments, reduces cycle times and eliminates secondary operations like cutting flash.
  • Dedicated applications engineering and process development team to advise on product design and deliver turnkey process solutions.
  • Global service team that can respond quickly in your time of need
  • One stop shop for machines, tooling, development and protoypes

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Applications

Catheter Butt Weld
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Butt Welds

Butt Welds

Butt welded tube segments are a standard method of creating multi-segmented catheters for diverse applications. Single and multiple lumen configurations are commonplace. They all require precise external geometric configurations with securely bonded interfaces for proper functioning of the catheter. A wide variation in tube sizes, tip configurations and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr and larger
  • Geometry Configurations: standard radius tip thermally bonded to main catheter shaft
  • Segment Lengths: Lengths ranging from 4 mm and longer
  • Materials: Virtually all thermoplastic polymers can be butt welded: including LDPE, HDPE, PE copolymers, PP, PU & PU blends, PEBAX, FEP, and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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Catheter Overlap Weld on Vante and PlasticWeld Systems equipment
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Overlap Welds

Overlap Welds

Overlap welded tube segments are a standard method of creating multi-segmented catheters for diverse applications. This method maximizes the melt interface between the two tube segments to enhance the joint’s integrity. They all require precise external geometric configurations with securely bonded interfaces for proper functioning of the catheter. A wide variation in tube sizes, overlap configurations and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr and larger
  • Geometry Configurations: tapered overlap joint
  • Overlap Lengths: Lengths ranging from 1 mm and longer
  • Materials: Virtually all thermoplastic polymers can be butt welded: including LDPE, HDPE, PE copolymers, PP, PU & PU blends, PEBAX, FEP, and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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Catheter braid to non-braid weld on Vante and PlasticWeld Systems equipment
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Braid to Non-Braid Welds

Braid to Non-Braid Welds

Butt welds between braided and non-braided tube segments are a standard method of creating kink-resistant catheters for diverse applications. The inclusion of braiding in the main catheter segment presents unique challenges in obtaining sufficient joint strength. All require precise external geometric configurations with securely bonded interfaces for proper functioning of the catheter. A wide variation in tube sizes, braid configurations, tube lamination constructions and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr and larger
  • Geometry Configurations: single lumen tubes thermally bonded together
  • Segment Lengths: Lengths ranging from 4 mm and longer
  • Materials: Virtually all thermoplastic polymers can be butt welded: including LDPE, HDPE, PE copolymers, PP, PU & PU blends, PEBAX, FEP, and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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Needle Guide with Plastic to Metal Bond
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Plastic to Metal Joining

Plastic to Metal Joining

Mechanical joining of plastic extrusions to machined steel components a standard method for creating components that require the strength of steel fitments and the flexibility of polymeric extrusions. The dissimilarity of the two materials presents unique challenges in obtaining sufficient joint strength. All require precise external geometric configurations and thermal profiling to assure maximum joint strength. A wide variation in tube sizes, joint designs and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 22ga and larger
  • Geometry Configurations: single lumen tubes
  • Materials: Virtually all thermoplastic polymers: including LDPE, HDPE, PE copolymers, PP, PU & PU blends, PEBAX, FEP, and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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soft tips
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Soft Tip

Soft Tip

Soft, bonded tips are a standard configuration for many catheter applications.  Their precise external and internal geometric configurations, along with the need for a securely bonded interface, are critical to proper functioning of the catheter and patient comfort.  Soft tips require a precise, repeatable process to be formed accurately and reliable, maximum strength bonding. A wide variation in tube sizes, tip configurations and polymer choices add extra layers of complexity to the tip forming process.  Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr up to 45Fr
  • Geometry Configurations: Including thin-walled tips, profiled ID transitions, thick walled and stepped OD’s.
  • Taper Lengths: Tip lengths ranging from 1mm up to 15mm
  • Materials: Most thermoplastic polymers can be formed: including PU & PU blends, PEBAX and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.
  • Customized tooling enhancements to provide precise positioning of critical internal features

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Catheter balloon bond
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Balloon Bonding

Balloon Bonding

Many catheters utilize balloons to help stabilize their location after deployment. The balloons must be securely attached to the catheter tube and provide a leak-free seal to assure proper functioning. Thermal bonding of the balloon’s stems to the catheter is possible when both are produced from similar or compatible polymers. Thermal bonding eliminates the use of dangerous solvents or adhesives, and enables profiling the exterior shape of the welded area. A wide variation in tube sizes, balloon configurations and polymer choices add extra layers of complexity to the bonding process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr and larger
  • Geometry Configurations: overlap joint
  • Overlap Lengths: Lengths ranging from 4 mm and longer
  • Materials: Virtually all thermoplastic polymers can be welded: including PP, PU & PU blends, PEBAX, PVC, and many others.
  • Standard Machine Configurations: 1-up

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Catheter hub weld on Vante and PlasticWeld Systems equipment
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Hub Welds

Hub Welds

Thermal bonding of plastic extrusions to molded plastic hubs avoids the use of solvents or adhesives while providing a superior strength joint. Polymers must be compatible and suitable for heat bonding. Differences in wall thicknesses between the tube and the hub create unique challenges. Precise external geometric configurations and thermal profiling help assure maximum joint strength. A wide variation in tube sizes, joint designs and polymer choices add extra layers of complexity to the bonding process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 22ga and larger
  • Geometry Configurations: single lumen tubes
  • Materials: Usually restricted to PVC, PU and EVA.
  • Standard Machine Configurations: 1-up

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Strain Reliefs

Strain Reliefs

Thermal bonding of overlapping plastic extrusions to catheter shafts forms a thickened wall section that helps avoid kinking of the main catheter tube in high stress areas. Polymers must be compatible and suitable for heat bonding. Differences in wall thicknesses between the exterior tube and catheter shaft create unique challenges. Precise external geometric configurations and thermal profiling help assure maximum joint strength. A wide variation in tube sizes, joint designs and polymer choices add extra layers of complexity to the bonding process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 22ga and larger
  • Geometry Configurations: single lumen tubes
  • Materials: Virtually all thermoplastic polymers can be welded: including PP, PU & PU blends, PEBAX, PVC, and many others.
  • Standard Machine Configurations: 1-up

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Catheter taper Weld on Vante and PlasticWeld Systems equipment
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Taper Welds

Taper Welds

Taper welded tube segments are a standard method of transitioning from a larger to smaller diameters for many catheter applications. Precise external and internal geometric configurations with securely bonded interfaces are critical for proper functioning of the catheter. A wide variation in tube sizes, taper configurations and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr and larger
  • Geometry Configurations: straight walled taper, single lumen
  • Segment Lengths: Lengths ranging from 4 mm and longer
  • Materials: Virtually all thermoplastic polymers can be butt welded: including LDPE, HDPE, PE copolymers, PP, PU & PU blends, PEBAX, FEP, and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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Marker Band Embedding
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Marker Band Embedding / Placement

Marker Band Embedding / Placement

Inclusion of marker bands is a critical feature that aids the physician in visualizing placement of the catheter inside the patient’s body. Their precise placement and encapsulation within the catheter tube walls are critical to proper functioning of the catheter. These features require a precise, repeatable process to assure locational accuracy and device integrity. A wide variation in tube sizes, tip configurations and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr up to 45Fr
  • Geometry Configurations: Including thin and thick-walled tubes, profiled ID transitions
  • Joint Lengths: joint lengths ranging from 1mm up to 8 mm
  • Materials: Typical thermoplastic polymers used include: PP, PU & PU blends, PEBAX and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.
  • Customized tooling enhancements to provide precise positioning of critical internal features

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Catheter Angiographic Tip
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Angiographic

Angiographic

Angioraphic tips require precise external geometric configurations, along with the need for a securely bonded interface, are critical to proper functioning of the catheter.  They require a precise, repeatable process to be formed accurately and while providing reliable, maximum strength bonds. A wide variation in tube sizes, tip configurations and polymer choices add extra layers of complexity to the tip forming process.  Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 2Fr up and larger
  • Geometry Configurations: standard radius tip thermally bonded to main catheter shaft
  • Taper Lengths: Tip lengths ranging from 1mm up to 15mm
  • Materials: Most thermoplastic polymers can be formed: including PU & PU blends, PEBAX and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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Needle Guide with Plastic to Metal Bond
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Needle Guide

Needle Guide

Mechanical joining of plastic extrusions to machined steel components a standard method for creating needle gudes. The dissimilarity of the two materials presents unique challenges in obtaining sufficient joint strength. All require precise external geometric configurations and thermal profiling to assure maximum joint strength. A wide variation in tube sizes, joint designs and polymer choices add extra layers of complexity to the tip forming process. Vante and PlasticWeld diverse equipment options provide you with unmatched versatility to meet your specific production challenges.

  • Tube OD Range: Tube sizes ranging from 22ga and larger
  • Geometry Configurations: single lumen tubes
  • Materials: Virtually all thermoplastic polymers: including LDPE, HDPE, PE copolymers, PP, PU & PU blends, PEBAX, FEP, and many others.
  • Standard Machine Configurations: 1-up, 2-up and 4-up systems depending on project details.

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Equipment

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Vante Ruby

Turnkey, High-Volume Production Equipment

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Vante Saffire

Turnkey, Precise Production Equipment

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Vante Jade

Flexible platform which allows for custom molds

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PlasticWeld Systems HPS-EM

Desktop R&D platform

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PlasticWeld Systems HPS-05 DB
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PLASTICWELD SYSTEMS HPS10-MXP

PLC controlled production equipment

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  • A MACHINE SOLUTIONS COMPANY
  • Vante
  • 100 N Tucson Blvd.
  • Tucson, AZ 85716 USA
  • 520-881-6555
  • A MACHINE SOLUTIONS COMPANY
  • PlasticWeld
  • 3600 Coomer Road
  • Newfane, NY 14108
  • 716-778-7691