TE Connectivity has unveiled an advanced 3D printing process that could significantly change how medical catheters are manufactured. Developed at the company’s PROPELUS Prototype Center in Galway, Ireland, the new technology automates one of the most labor-intensive steps in catheter production while maintaining the same performance and quality as conventional manufacturing.
Catheters used in cardiovascular, neurovascular, endoscopic, and electrophysiology procedures require different levels of flexibility along their length. Traditionally, manufacturers create these varying sections separately before manually assembling them onto the catheter shaft. This multi-step process is time-consuming, labor-intensive, and limits design flexibility.
TE Connectivity’s new additive manufacturing process eliminates much of that manual work by directly depositing polymer material onto the rotating catheter shaft. The automated approach allows engineers to precisely control the geometry, thickness, and mechanical properties of each section while simplifying the overall manufacturing process.
Beyond improving production efficiency, the technology offers greater design freedom for future medical devices. Engineers can rapidly prototype new catheter designs, explore more complex structures, and develop devices that would be difficult or impossible to manufacture using traditional methods.
The company also expects the process to reduce production costs, simplify supply chains, and lower material waste. By applying polymer only where it is needed, the technology improves material efficiency while supporting more sustainable manufacturing practices.
This innovation represents another important milestone for medical additive manufacturing. Rather than using 3D printing solely for prototypes, manufacturers are increasingly adopting the technology as part of full-scale production, demonstrating its growing reliability and commercial value.
As healthcare continues to demand smaller, more sophisticated minimally invasive devices, additive manufacturing is becoming an essential tool for accelerating innovation. TE Connectivity’s new process highlights how 3D printing is transforming medical manufacturing by enabling faster development, greater customization, and improved production efficiency for next-generation medical technologies.
