New 3D printing process helps medical device manufacturers accelerate catheter development, improve consistency and enable new design possibilities.
Published
07/20/26
GALWAY, Ireland – July 20, 2026
TE Connectivity, a world leader in connectors and sensors, has introduced a new automated 3D printing process to manufacture the catheter shafts it supplies to medical device manufacturers. It will replace a higher-cost, predominately manual assembly process commonly used across the industry.
Catheters often require multiple polymer jacket sections with different flexibility characteristics along the length of the device. The new technology, developed by the Advanced Technology Group within TE’s Medical business at the PROPELUS Prototype Center in Galway, Ireland, applies the polymer sections directly onto the catheter shafts during production, resulting in a quicker and more consistent manufacturing process. The resulting catheter shafts have the same mechanical properties, materials and aesthetics as those made by traditional methods.
“This work reflects TE’s continued focus on advancing manufacturing innovation to help our customers develop increasingly sophisticated minimally invasive medical devices,” said Pat Duane, senior vice president and general manager of the Medical business. “We believe additive manufacturing technologies have the potential to expand design possibilities, accelerate development and support the future of catheter manufacturing.”
The new process will allow catheter manufacturers to speed up the development of new devices by allowing TE’s engineering teams to iterate designs more quickly. It may also create opportunities for these manufacturers to introduce new catheter constructions and device architectures that are impractical to manufacture using conventional techniques.
“This process, along with complementary disruptive processes in development, will result in a paradigm shift in catheter manufacturing for our customers. It has the potential to significantly reduce product costs, simplify supply chains and have a positive environmental impact,” said Medical Engineering Fellow Bernard McDermott.
About TE Connectivity
TE Connectivity plc (NYSE: TEL) is a global industrial technology leader creating a safer, sustainable, productive, and connected future. As a trusted innovation partner, our broad range of connectivity and sensor solutions enable the distribution of power, signal and data to advance next-generation transportation, energy networks, automated factories, data centers enabling artificial intelligence, and more. Our more than 90,000 employees, including 10,000 engineers, work alongside customers in approximately 130 countries. In a world that is racing ahead, TE ensures that EVERY CONNECTION COUNTS. Learn more at www.te.com and on LinkedIn, Facebook, WeChat, and Instagram.
