Intricate geometries are machined with minimal variability using an ultrafast process, company says
HIGHLAND HEIGHTS, Ohio—A new laser machining process currently in use at a prominent medical device contract manufacturing company is said to create highly precise features in materials, such as bio-absorbable polymers, shape memory metals, and other exotic alloys, without producing any heat affected zone (HAZ). The athermal laser machining process, known as Noble UltraLight™, was introduced by Norman Noble, Inc., last fall to support the advanced manufacturing requirements of the company’s customers in the medical and aerospace industries. By employing what the company calls an ultra-short pulse (USP) laser, the process can reduce or, in some cases, eliminate costly deburring and post-processing steps because it doesn’t generate a heat-affected zone. The resulting benefits, according to the company, include increased product quality and yield.
“We are very excited about integrating the new UltraLight Laser into our operation and applying the unique advantages that this technology offers to meet our medical and aerospace customers’ production specifications,” said Dan Stefano, vice president of manufacturing for Norman Noble, Inc., in a statement released by the company. “Its unique Nitinol- and polymer-cutting abilities enable us to supply our customers with the most technologically advanced processes offered in the industry.”
Described as an “ultra-fast laser process,” Noble UltraLight can be used to machine precise features in vascular stents with “minimal variability” and without introducing the heat inherent in traditional thermal laser manufacturing, according to the company. For these reasons, the company says, the technology represents “a dramatic advancement” in the manufacturing of stents and other medical device applications, including drug delivery systems, catheter devices, valves, and needles.
“UltraLight is another giant leap forward for manufacturing technology within the United States,” said Chris Noble, vice president of Norman Noble, Inc. “A laser system capable of cutting the tightest, most intricate geometry through virtually any material without generating any thermal damage to the material was once unimaginable to most design engineers. Engineers had to design their products around removal of this thermal damage or use less than optimal materials. Today, Norman Noble has brought this athermal concept out of the laboratory and into the hands of our experienced staff of laser technicians.
“We look forward to demonstrating our new Noble Ultralight laser cutting system’s capabilities to our customers and shortening their time to market for implantable devices,” he added. “Most importantly, we’re excited by the benefits their patients will realize worldwide.”
Norman Noble (www.nnoble.com) manufactures medical devices and implants to customer specifications in compliance with FDA regulations and ISO 9001 and ISO 13485. Manufacturing processes used by the company include laser machining and welding, Swiss turning and milling, conventional and wire EDM, high-speed 7-axis contour milling, Nitinol shape setting, and clean room assembly and packaging. The company also offers prototype services in separate, fully dedicated departments.
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