Specialty Needles

Specialty Needles

Minimally invasive medical procedures require sophisticated needles. Endoscopic biopsies, implantations, and transceptal punctures demand complex needle components that must meet exceptionally high standards for strength, puncture ability, and finishes.

With a wide array of products, materials, and expertise, TE caters to the needs of medical device and life sciences companies. By partnering with TE at any stage, from design to high-volume production, you gain several advantages: 

 

  • Extensive experience: We have senior metallurgists and polymer scientists on staff, each with decades of experience to support your needle development.  
  • Access to a vast inventory of materials: Our solution includes capabilities for wire and tubing needed to build your needle assembly. These materials are available in several types, including Javelin®; a material specifically engineered for medical use.
  • Complete customization: From proximal to distal, your needle can be built to your exact specifications. This includes needle points, trocars, and stylets that can be modified with cuts, bends, roughening, over-jacketing—any type of processing you can imagine.
  • Sophisticated manufacturing process:  The equipment, processes, and most importantly, the experience of our team, make it possible to create virtually any needle design in any quantity required. 

 

Materials

TE offers standard and unique materials for needle components.  

  • JavelinTM – A proprietary material that creates superior resilience, especially for medical components. Needles created with Javelin are unique in that they are capable of multiple punctures, making them ideal for medical uses/biopsies. 
  • Stainless Steel – Both 304 (medical grade) and 316 (enhanced corrosion resistance) grades are typically used for medical components. 
  • Nitinol – A Nickel-Titanium shape memory alloy that possesses the remarkable capability to remember its original shape and effectively return to it when exposed to heating. Additionally, Nitinol exhibits impressive elasticity under stress, enabling it to deform substantially and then recover its initial form when the stress is relieved. 

Tolerance

Materials can be engineered within the following parameters:

  • Size range: 7 – 26 Gauge 
  • Wall thickness: RW, TW, XTW  
  • Lengths: Up to 2250mm  

Expertise

Working with the TE team, you can:  

  • Accelerate product development 
  • Optimize development and production controls 
  • Get products to market faster  

 

The TE team is made up of project managers, design engineers, mechanical and industrial engineers, biomedical engineers, material scientists (metals and polymers), and QA/Regulatory personnel.

 

To achieve the precision required for needle assemblies, two things are required. The first is machinery sophisticated enough to create the desired end product. The second, and more important of the two, is experience. The knowledge and skill of industry professionals who understand the material science involved so well and have such extensive experience that they can produce astonishingly precise components. 

Value-Added Services

The TE team can guide you through the entire process from design to production, including:

  • Prototyping development 
  • Concept development 
  • Feasibility builds 
  • Design freeze 
  • Design verification 
  • Validation  
  • Clinical build 
  • Volume manufacturing 

Manufacturing Capabilities

Metal Components

  • Burr-free cutting 
  • Micromachining 
  • ECGM grinding (Javelin™, stainless steel, nitinol) 
  • Laser processing (cutting, welding, and marking) 
  • Coating 
  • Bending 
  • Swaging 
  • Brazing 
  • Electrochemical marking 
  • Laser marking (pad printing, laser marking, chemical etching) 
  • Echogenic profiling 
  • Surface roughening 

Cleaning & Assembly

  • Ultrasonic cleaning and passivation 
  • Electropolishing 
  • UV and epoxy bonding 
  • Nitinol bonding 
  • Soldering 
  • Laser welding and micro-welding 

Molding

  • Injection and insert molding 
  • Overmolding 

25+

years of experience in needle production

FDA

FDA-registered contract manufacturer

ISO

Manufacturing is fully accredited to ISO13485