Laser Processing


Laser Processing

State-of-the-art laser welding and micromachining capabilities add value to our catheter and guidewire manufacturing, giving you more options for materials and design.

Medical device OEMs rely on TE’s precision medical device manufacturing and assembly services. We are experts in laser cutting, laser welding, laser ablation and laser marking. TE components and assemblies are used in a variety of medical devices including coronary, peripheral and neurovascular devices, stimulation leads, surgical instruments, dental and orthopedic devices. Good manufacturing practices and tight process controls are applied to all our customers’ applications. No filler materials are added during the laser process, eliminating biocompatibility issues for medical submissions.

Laser Cutting

Precision cutting of materials such as plastic or metal tubing is one of our many strengths. 


  • Tolerances within 0.0005" or less
  • Kerf width as small as 0.0007"
  • Process small wall thicknesses as thin as 0.002" up to 0.030"
  • Process diameter tubing (i.e. 0.012" x 0.009")
  • Fast, repeatable processes
  • Laser processes cost less than machining or EDM methods


  • Stainless steel
  • Nickel
  • Cobalt chromium
  • MP35N

Laser Cutting/Ablation (Polymers):

  • Requires little to no secondary cleaning processes
  • Tolerances within 0.001" or less
  • Drill holes as small as 0.002" or less
  • OD reduction on polymer components and assemblies
TE Laser Cut
2 Laser Cut Stents

Laser Welding

TE's lean manufacturing practices and tight process controls are applied to all of our customers' applications. No filler materials are added during laser processing, which removes biocompatibility issues for medical submissions.


  • Minimal heat-affected zone around weld site
  • Fast, repeatable laser processes for consistent quality
  • Contact-free processing helps prevents stress on materials
  • Dissimilar metals can be welded together
  • Laser beam can be positioned into tight geometry


  • Guidewires
  • Laser welded torque cables
  • Laser wire ball forming
  • Laser welded catheter tips
  • Nitinol welding
  • Laser welded tube assemblies
  • Lap and butt welding
  • Laser welded nitinol assembly
  • Helically laser welded coils
  • Hermetic weld joints
  • Laser welded filter assemblies

Materials that can be welded include:

  • Similar and dissimlar metal welding
  • Stainless steels: 304, 316, 17-4, 420, 302, 303 and others
  • Nitinol
  • Platinum and platinum alloys
  • Titanium
  • ELGILOY™ alloy, nichrome, INVAR™ alloy, MP35N™
  • L605
Pull-Ring Assemblies
Laser Weld


Femtosecond laser micromachining is useful for single-step laser processing of multiple materials in medical device applications. Custom designed to be flexible and suitable for on- or off-axis cutting and R&D or volume applications, it can handle both flat stock and tube cutting on the same system with minimal setup. This capability creates new opportunities for advanced micro designs, particularly for difficult-to-process metals, drilling and cutting high-precision holes and shapes free from thermal damage, which are not feasible with conventional lasers.

Advantages of Femtosecond Laser Processing

  • Cuts or drills multiple materials and layers at one time (metal or polymer)
  • Drills and cuts micro shapes
  • OD reduction on metal and polymer components and assemblies (i.e. catheters)
  • Materials and composites including polymers, platinum, stainless steel, nitinol and more
  • Custom designed system for on- or off-axis work
  • Suitable for R&D or volume applications
Laser Cut

Plastics Laser Processing

Laser cutting plastic is fast, clean and accurate and requires minimal tooling. Our dedicated laser workstations enable quick turnaround for prototyping and production.

Materials as thin as 0.002" and as thick as 0.040" may be laser processed, including:

  • Silicone
  • Polyurethane
  • PEBA
  • PTFE
  • ETFE
  • PET
  • Polyimide
  • Polyester fabric, and many others
Laser Ablated Shaft
Silicone Laser Cut

Equipment Capabilities

  • 26,000 square feet housing medical device development processes
  • Laser systems
  • Testing equipment
  • Finishing/processing
  • Inspection
  • In-house machining/toolmaking