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Last Updated:
December 2, 2025
In the dynamic field of medical device engineering, rapid prototyping and research and development (R&D) are vital stages for innovation and optimization. As engineers explore alternatives to traditional reinforcement methods like braid and coil, laser cut hypotubes have emerged as a promising option. In this blog post, we will delve into the effectiveness of laser cut hypotubes as an alternative for rapid prototyping and R&D, evaluating their advantages and considerations in these critical stages of medical device development.
Design Flexibility and Customization: Laser cut hypotubes offer exceptional design flexibility, making them highly suitable for rapid prototyping and iterative design processes. Engineers can easily modify and customize the cut pattern on the hypotube's surface, tailoring the mechanical properties of the catheter shaft to meet specific performance goals. This flexibility enables rapid exploration of multiple design iterations and the evaluation of different concepts efficiently.
Precise and Consistent Manufacturing: Laser cutting technology ensures precise and consistent manufacturing of hypotubes, enabling accurate replication of desired features across multiple prototypes. This level of manufacturing consistency is critical during the rapid prototyping stage, where engineers need reliable and repeatable results for thorough evaluation and validation. Laser cut hypotubes provide a high degree of predictability in terms of dimensions, structural integrity, and performance, enhancing the reliability of prototypes.
Streamlined Iterative Testing: The quick turnaround time facilitated by laser cut hypotubes accelerates the iterative testing process during R&D. Engineers can efficiently fabricate multiple prototypes with different designs, enabling comparative testing and evaluation of various mechanical properties, such as bend radius, kink resistance, and pushability. This streamlined iterative testing expedites the optimization of catheter designs, leading to faster progress in R&D efforts.
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Manufacturing Costs: You should consider the cost of producing laser-cut hypotubes during rapid prototyping and R&D. These parts require specialized processes and skilled technicians, which adds expense for small or early-stage projects. Even so, fast turnaround and fewer design cycles save you time and resources. When you factor in a quick 3–5 day delivery window, the gains often outweigh the upfront cost.
Limited Availability of Design Guidelines: Compared to traditional reinforcement methods like braid and coil, the availability of design guidelines and standards for laser cut hypotubes may be relatively limited. This can pose challenges during the R&D process, as engineers may need to rely on their own expertise and experimentation to determine optimal laser cut patterns for specific applications. This can be easily overcome by collaborating with the laser cutting experts at Symmetry Laser who will partner with your team to get the right LCHT for your project, every time.
Manufacturing Expertise and Equipment: Successfully utilizing laser cut hypotubes for rapid prototyping and R&D requires specialized manufacturing expertise and access to laser cutting equipment. It is essential to collaborate with experienced manufacturers who possess the necessary capabilities and knowledge to translate design specifications into high-quality laser cut hypotubes. Building strong partnerships and leveraging external resources can help overcome potential manufacturing challenges.
The Symmetry Laser Engineering team combines for more than 60 years of industry experience designing and manufacturing the most innovative and dependable laser cut hypotubes (LCHT). The Symmetry Engineering team is dedicated to providing its customers with effective catheter solutions that enable life saving devices.
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