Automated Catheter Coating and Curing System

CASE STUDY

Automated Catheter Coating and Curing System

Medical Device

Client Challenge:

A medical device manufacturer sought to automate and optimize their catheter coating and curing process to improve product quality, consistency, and production throughput. The existing manual process was labor-intensive, time-consuming, and prone to inconsistencies due to human error. The manufacturer needed a solution that could precisely control the coating application, ensure uniform curing, and minimize material waste.

Our Solution:

We designed and implemented a fully automated catheter coating and curing system. Saber Engineering was responsible for the entire project scope, from design and engineering to procurement, construction, and installation.

Automated Catheter Coating & Curing System Features:

01.

The System

The system incorporated a robotic arm for precise catheter manipulation, a custom coating applicator for controlled coating deposition, and a UV curing station for rapid and uniform curing. The system also included a carrier system for holding multiple catheters, a multi-axis elevator table system for precise positioning, and optical sensors for fill level detection and quality control.

02.

Coating Solution Delivery

A peristaltic pump delivered the coating solution to the filling manifold, ensuring accurate and consistent application. Each catheter had its own dipping well with a discrete alarm sensor to monitor fill levels and prevent clogging. An analog liquid level sensor in a monitoring well maintained the desired liquid volume in the reservoirs, minimizing waste.

03.

UV Curing

The system utilized UV curing technology to rapidly and uniformly cure the coating, ensuring optimal performance and longevity of the catheters. The curing process was precisely controlled to meet the specific requirements of the coating material.

04.

Robotic Automation

A robotic arm picked and placed the catheter carriers in the respective stations, eliminating manual intervention and ensuring consistent processing. The robot's flexibility allowed for easy adaptation to different catheter sizes and configurations.

05.

Control System

A programmable logic controller (PLC) managed the entire system, coordinating the robot, coating applicator, UV curing station, and other components. A touchscreen interface provided operators with real-time system status, control options, and data logging capabilities.

The Results:

The implementation of the automated catheter coating and curing system resulted in significant improvements for the medical device manufacturer. The automated process eliminated manual labor, reducing the risk of errors and ensuring consistent coating quality and curing results. The precise control of the coating application and UV curing process minimized material waste, resulting in cost savings. The system's high throughput capability significantly increased production capacity, meeting the manufacturer's growing demand. The integration of sensors and quality control measures ensured the production of high-quality catheters that met stringent regulatory requirements.