Advanced coatings and laser ablation for high-performance materials in medical devices

Mon, 24 Aug 2026 12:00:00 Z

Medical device conductors often need to perform multiple functions within a single assembly. One section may need to transmit electrical signals, another must move smoothly through a lumen, and another may require direct contact with tissue. Advanced coating technologies help meet these competing demands by providing electrical insulation, reducing friction, improving durability, or combining several benefits in the same device. Materials such as ETFE, PFA, FEP, PTFE, and polyimide each offer unique performance characteristics that allow engineers to balance dielectric strength, flexibility, lubricity, abrasion resistance, and size constraints based on application requirements. [2026-232_F...s_v3.0 (1) | PDF]

Selecting the right coating is only part of the solution. Many medical devices require coatings to be removed at specific locations to allow for welding, sensing, stimulation, or electrical connections. Laser ablation provides a precise, non-contact method for removing coatings without damaging the underlying conductor. Unlike traditional mechanical stripping, laser ablation minimizes the risk of conductor damage while enabling highly controlled exposure windows along a wire’s length. This capability supports advanced device designs, including multi-electrode configurations and complex conductor geometries used in neurostimulation, diagnostic, and catheter-based applications. [2026-232_F...s_v3.0 (1) | PDF]

The greatest value comes from combining coating technologies and laser ablation strategies to match the functional demands of each section of a medical device. For example, conductors may use dielectric coatings for insulation, lubricious coatings to improve device navigation, and selectively ablated regions for electrode contacts or terminations. By tailoring polymer selection, coating thickness, and exposure locations, engineers can optimize device performance while meeting demanding anatomical and functional requirements. Fort Wayne Metals partners with device designers to evaluate these trade-offs and develop coating and ablation solutions that support next-generation medical technologies.

The challenge of finding a Nitinol alternative

Mon, 23 Nov 2020 15:09:00 Z

Nitinol has long been the material of choice for medical devices that require super-elasticity. Its ability to recover from deformation without permanent damage makes it essential in applications like stents, guidewires, and orthopedic implants. However, concerns over Nitinol’s nickel content with potential allergic reactions from patients have driven research into alternative materials with comparable properties.

The rise of Ni-free β-Ti alloys

One promising alternative is a Ni-free β-Ti alloy composed of Ti-40Hf-13Nb-4.5Sn (wt.%). This alloy demonstrates large and stable super-elastic behavior at room temperature, a key requirement for medical applications. Unlike other β-Ti alloys that struggle to achieve the recoverable strain of Nitinol, this material exhibits up to 5.3% total recoverable strain at 6% deformation—putting it much closer to Nitinol’s performance.

Key advantages of Ti-Hf-Nb-Sn (THNS) alloy

This Ni-free β-Ti alloy offers several advantages beyond eliminating nickel:

Comparable mechanical properties: Its mechanical strength and fatigue performance are in the same range as superelastic Nitinol.
Customizable plateau strengths: Similar to Ni-rich Nitinol, the alloy's performance can be adjusted through low-temperature aging.
Manufacturability at scale: The alloy has been successfully produced in 100 kg quantities using commercial production lines, making it feasible for industrial-scale applications.
High X-ray visibility: The presence of hafnium enhances radiopacity, which is beneficial for medical imaging during procedures.
Biocompatibility and corrosion resistance: These characteristics make it a strong candidate for implants, especially for nickel-sensitive patients.

Overcoming manufacturing challenges

Many β-Ti alloys have struggled with manufacturability due to high heat treatment requirements and oxidation concerns. However, this alloy achieves optimal mechanical properties at lower temperatures (~600°C), reducing the risk of oxidation and making shape-setting more practical. Unlike other high-zirconium β-Ti alloys, which pose ignition risks during processing, this alloy has demonstrated safer large-scale production capabilities.

A substitute for Nitinol?

Despite years of research, no Ni-free β-Ti alloy has been successfully substituted for Nitinol in the medical device industry—until now. With its stable super-elasticity, comparable mechanical properties, and improved manufacturability, this Ti-Hf-Nb-Sn alloy presents a viable alternative for applications such as orthopedic implants, dental devices, and neurovascular components.

As the medical industry continues to prioritize patient safety and material innovation, this breakthrough may pave the way for the next generation of superelastic biomaterials.

Fort Wayne Metals - Technical Blog

Advanced coatings and laser ablation for high-performance materials in medical devices

The challenge of finding a Nitinol alternative