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Conair and Partners Showcase Multi-lumen Catheter Production at MD&M WestConair and Partners Showcase Multi-lumen Catheter Production at MD&M West

Conair is working with Davis Standard and Zumbach Electronics to demonstrate extrusion of small, tapered, multi-lumen surgical catheters made from TPE at the event.

David Hutton

January 22, 2025

3 Min Read
cross-sectional detail of catheter
The cross-sectional detail of the catheter is shown here, highlighting the small center lumen with an inner diameter measuring 0.005 in.Image courtesy of Conair

Conair Group, in collaboration with technology partners Davis Standard and Zumbach Electronics, will spotlight a complex and highly precise medical manufacturing process at MD&M West 2025: The extrusion of small, tapered, multi-lumen surgical catheters made from thermoplastic elastomer (TPE).

MD&M West is set for Feb. 4 to 6, 2025, at the Anaheim Convention Center in Anaheim, CA. The event is North America’s largest annual manufacturing trade show, covering the medtech, plastics, automation, and design and manufacturing sectors.

This live demonstration will take place at booth 4320, and will spotlight the capabilities required to produce the precision tubing used in minimally invasive surgeries and medical procedures.

Multi-lumen catheter extrusion

The catheter segments being produced during the show are considered to be an engineering challenge. Each segment requires continuous dimensional control, both externally and internally, to meet the exacting standards of medical device manufacturing. Over a length of 24 in., the outer diameter of the catheter tapers from 0.140 in. at the body to just 0.110 in. at the tip. 

Inside, the catheter contains three lumens: two crescent-shaped outer lumens and a central lumen with an internal diameter of only 0.005 in. According to the company, these lumens must maintain precise dimensions as they taper along with the outer tube, all while ensuring the tube’s outer wall remains consistent.

Related:Plastics Processing Efficiency in Spotlight at MD&M West

At MD&M West, the live demonstration will feature a multi-step extrusion process. Medical-grade TPE and additive masterbatch will be fed into a Davis-Standard 1-in. High Performance (HPE) medical extruder via Conair AL-2 and TLM loaders, blended in a Conair TrueBlend TB45 blender. Temperature control and process cooling will be provided by a Conair EP1A portable chiller and a Thermolator TW-T temperature control unit.

The TPE extrudate is driven through a Guill cross-head die, where air inputs from three Zumbach SPV-1 digital airboxes are injected to inflate and pressurize the hot tube, creating the internal lumens. The extrudate then passes through a water-filled sizing/calibration tool, which uses a vacuum-controlled layer of water to gently shape the tube’s outer diameter without causing friction or damage.

From that point, the extrusion then continues into a Conair MedVac 238 vacuum cooling tank, where precise pressure regulation ensures laminar flow over the tube for optimal cooling. Zumbach UMAC ultrasonic devices measure the tube’s wall thickness, while the Zumbach ODAC laser measures its outer diameter, feeding real-time data into the line control system.

Creating a bump

Conair noted its Medline MLD1-12S puller/cutter unit regulates the variations in line speed and air pressure that create the catheter’s tapered “bump.” The company’s software manages these adjustments, enabling the creation of multi-lumen designs with up to 16 lumens. The puller/cutter system’s air-assisted cutter bushings minimize friction, ensuring consistent, clean cuts for each catheter segment.

The company noted that after cutting, finished catheters are conveyed via its Medline MTAC 406 conveyor. While the extrusion process results in small scrap segments at transition points, these are collected, granulated, and reintroduced into the process at a 10 to 20% ratio, ensuring a zero-waste production cycle.

For more information about Conair Group’s products and services, visit www.conairgroup.com.

About the Author

David Hutton

David Hutton is a journalist with more than 25 years of experience as an editor and writer with daily newspapers and trade publications. 

A Kent State University graduate, he was born in Canton, Ohio, and is a lifelong writer. David started his professional career as a reporter and page designer with the Parkersburg Sentinel in Parkersburg, West Virginia. He returned to his hometown, taking a role with the Massillon Independent, where he rose to the position of managing editor.

David’s career next took him to October Research Corp., where he worked for trade publications in the real estate settlement services industry before returning to daily newspapers as news editor for The Times-Reporter in Dover-New Philadelphia, Ohio. While there, he oversaw design of the newspaper and won an Associated Press award for Best Page 1 Design. 

In 2012, David joined the staff of Plastics News as research analyst. He was responsible for the production of data research reports providing analysis of various segments and end markets of the plastics industry. He also produced content for the publication. 

In 2019, David joined Ophthalmology Times, serving as managing editor of the publication covering the latest advancements in the ophthalmology industry for physicians and clinicians. 

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