Modern medicine is constantly pursuing the development of minimally invasive surgery and diagnostic procedures. This poses a major, continuing challenge for medical device manufacturers to increase the miniaturization of their components. Providing important power and data connectivity for these micro devices is driving new Development of a miniature cable with a diameter of only 0.1 mm or less.
Recently, the market is changing with the introduction of Nexans' NEWSENSE® series of micro-cables. Its insulation sheath thickness is only 15 μm.
Although medical microcables must ensure the necessary performance, reliability, and safety for any medical application, their size also plays a decisive role in reducing the impact of invasive operations. One of the main limiting factors for cable miniaturization is the Thickness. So far, with the 'standard' extrusion process, it is not possible to reach a thickness of 30 microns. Although at this size, the insulation is slightly thinner than the finest human hair (75-125 microns), it still occupies Diameter of 0.1mm cable is 84% of the entire cross section.
With its new extrusion process, Nexans is able to reduce the insulation thickness of its NEWSENSE® cable to 15 μm. This allows the manufacture of smaller diameter cables, offering a variety of advantages for invasive surgery. They are easier to insert into the catheter, For example for transcatheter applications in cardiovascular electrophysiology and neurology. When used for direct insertion into the body, such as pacemakers, they are less traumatic to the patient.
Another benefit of the new design is that it can integrate more cables within the same cross-section to improve performance. The extruded layer is also smoother, regular and aesthetically pleasing, and easy to stop stripping.
One of the first NEWSENSE® designs is a new space-saving cable for transcatheter applications. This design uses two AWG52 (20 micron copper diameter) insulated wires twisted together as a twisted pair. Shielding external electromagnetic interference by silver plating The 15 μm diameter wire in the copper alloy is provided. On the outside, the cable has a biocompatible, low-friction fluoropolymer sheath with a final outer diameter of 0.14 mm.
'The medical cable market has increased by about 5-10% year-on-year, and the development of new microcables will allow Nexans to strengthen its existing strong position and open up some exciting possibilities for new applications.' Nexans Medical Thierry Malvache, product manager, said, 'This project really promoted the development of extrusion technology. Its success is a recognition of the high level of cooperation between our medical cable factory and the Lyon Nexans Research Center.'
NEWSENSE® micro-cables and other medical cables will be produced at the Nexans Specialty Factory in Texas, France.