Custom Micro Trocar Manufacturing

Custom micro trocar manufacturing techniques are ushering in a new era of adaptability for healthcare and medical devices. Emerging technologies, such as femtosecond lasers, micro EDM, and multi-axis micro machining, allow for smaller and more complex trocar features. Coupled with advancements in micro-assembly such as insert-molding and micro-welding, these innovations are reshaping our ability to produce medical devices. This article dives into the transformative impact that these manufacturing technologies have on custom micro trocars. We’ll explore the potential these technologies have in meeting the diverse needs of modern medical device design.

Custom Trocar Manufacturing Methods

Innovative breakthroughs in custom micro trocar manufacturing technologies are revolutionizing the healthcare production. New and emerging methods enable unprecedented fine features and design versatility for custom micro instruments. As a result, these advancements create new possibilities in minimally invasive surgeries.

  1. Femtosecond Laser Technology: Femtosecond lasers, renowned for their ultra-short pulse durations, revolutionize the fabrication of micro trocars. By harnessing this technology, manufacturers can achieve unprecedented precision in cutting and shaping trocar components. Particularly beneficial for intricate tips and shafts, femtosecond lasers empower trocar designs to meet the demands of medical procedures. Their capability to handle complex geometries at the microscale opens new avenues for trocar design and manufacturing.
  2. Micro EDM (Electrical Discharge Machining): Micro EDM is a critical technology in the production of custom micro trocars. Through controlled electrical discharges, micro EDM can craft intricate features and fine details in trocar components, even at micro scales. This process furthermore facilitates the creation of trocars with sharp angles and precise geometries, addressing challenges posed by advanced medical procedures. With its ability to achieve intricate shapes, micro EDM empowers the development of trocars tailored to specific clinical needs.
  3. Multiaxis Micro Machining Centers: Multiaxis micro machining centers represent a cornerstone in the manufacturing of custom micro trocars. By enabling simultaneous movement along multiple axes, these advanced machining centers excel in creating three-dimensional and highly intricate trocar designs. This versatility is thus indispensable for adapting trocar specifications to diverse medical applications and accommodating the evolving requirements of healthcare professionals. Leveraging the capabilities of multiaxis micro machining centers, manufacturers can innovate trocar designs, optimize production processes, and deliver cutting-edge solutions that elevate surgical precision and patient care standards.
closed tip trocar with side hole

Advancements in Trocar Micro Assembly Techniques

  1. Micro Welding: Micro welding plays a pivotal role in the assembly of custom micro trocars. This technique allows for the precise joining of small metal parts such as micro machined metals or hypodermic tubing. Micro welding contributing to the overall functionality and strength of the trocar. Micro welding is particularly beneficial when working with materials that require highly controlled bonding. Micro welds ensure integrity in strength and hermeticity of the final product.
  2. Insert Molding: Insert molding is a technique that integrates plastic and metal components seamlessly into the trocar design. This method allows for the creation of reliable bonds, superior in manufacturability to that of adhesive bonding. Insert molding ensures quality and durability during medical procedures. The combination of micromanufacturing technologies with insert molding enables the production of intricate trocars with versatile plastic interconnecting features such as Luer Locks and more.

Trocar Outer Diameters as small as 0.05mm

Image of CAD Rendering

Transformative Impact on Medical Device Production

The convergence of micromanufacturing technologies and assembly techniques is revolutionizing our ability to produce custom micro trocars. As a result, the impact of these advancements is significant in several life changing areas:

  1. Minimally Invasive Procedures: Custom micro trocars enable the development of minimally invasive procedures by offering smaller, more precise entry points. This leads to reduced trauma for patients, faster recovery times, and improved overall procedural outcomes.
  2. Patient-Specific Solutions: The ability to create highly customized trocars allows for patient-specific solutions, addressing the unique healthcare needs of individuals. This personalized approach enhances the efficacy and safety of medical procedures.
  3. Evolution of Healthcare Technologies: The advancements in micromanufacturing and micro assembly are driving the evolution of healthcare technologies. As custom micro trocars become more tailored to specific applications, they contribute to the overall advancement of medical devices.
micro trocar tips

In need of custom micro trocar manufacturing? Let us help!

We manufacture micro components and assemblies in accordance with Medical Device and ISO regulations.

  • Extensive Quality Management Systems
  • ISO 13485:2016 Certified
  • Class ISO-7 Clean Room