Catheter construction begins with a core, or mandrel, upon which the catheter is built. Used to create or form the inside diameter (ID) during production, mandrels must provide consistent IDs and a smooth inner surface (lumen) for the finished catheter. Thus, choosing the right mandrel material for your design is critical.

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PTFE Monofilament

PTFE monofilament is a foundational mandrel material in catheter construction. PTFE’s ability to be manufactured with precise dimensional control, combined with its naturally smooth, non-stick surface, helps ensure consistent IDs and facilitates easy mandrel removal after the finished catheter is constructed.

Glass-Filled PTFE Monofilament

For designs requiring a higher PIC count braiding, the mandrel used during construction must be capable of withstanding the additional compressive forces caused by the braid. Glass particles can be compounded with PTFE resin prior to extrusion to enhance the mechanical properties of the extruded PTFE monofilament (or thick-walled tube). Both PTFE and Glass-Filled PTFE mandrels provide:

• High lubricity for easy removal
• High operating temperature [500 °F (260 °C)] for hot lamination environments
• Easier drawdown vs. PTFE-coated stainless steel

PTFE MONOFILAMENTS – TYPICAL CAPABILITIES
TYPE	OD RANGE	OD TOLERANCE	LUBRICITY	STIFFNESS
PTFE	0.004″ – 0.170″ (0.102 mm – 4.318 mm)	± 0.0005″ – 0.003″ (± 0.0127 mm – 0.076 mm)	★★★★★	★★★☆☆
Glass-Filled PTFE	0.006″ – 0.099″ (0.152 mm –2.515 mm)	± 0.0005″ – 0.003″ (± 0.0127 mm – 0.076 mm)	★★★★★	★★★★★

 

XpanCore™ Mandrels

For metallic laser-cut hypotubes, integrating liners within the hypotube assembly can be a complex and time-consuming process. Traditional methods often require exceptionally tight tolerances between the liner OD and the hypotube ID, as well as the use of pressurized systems or other complex techniques to secure the liner in place. These approaches can increase manufacturing complexity and lead to poor yields due to liner damage or incomplete bonding.

XpanCore™ mandrels were engineered specifically to address these challenges. Designed to expand when heat is applied, XpanCore™ mandrels are advanced processing aids that help simplify the construction of hypotube assemblies by alleviating issues with liner sizing, placement, and adhesion. Inserted into the ID of the liner, XpanCore™ mandrels expand outward when heat is applied, helping secure the liner against the inner walls of the hypotube during processing. This helps simplify liner integration while supporting more efficient and repeatable assembly processes.

• Heat-activated expansion
• Alleviates liner sizing challenges
• Facilities liner placement and optimal adhesion during processing

XPANCORE™ MANDRELS – TYPICAL CAPABILITIES
TYPE	OD RANGE	OD GROWTH	LUBRICITY	STIFFNESS
FEP or PFA	0.010″ – 0.267″ (0.254 mm – 6.782 mm) As supplied	10% – 30%, design dependent	★★★★☆	★★★☆☆

 

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