New Heat-Activated Mandrels Help Address Liner Sizing, Placement, and Adhesion Challenges In Advanced Catheter Manufacturing

Orangeburg, S.C. – (June 10, 2026) – Zeus, a global leader in advanced polymer solutions and catheter manufacturing, today announced the launch of XpanCore™, a new, heat-activated mandrel technology designed to help simplify the construction of metallic laser-cut hypotube assemblies.

Laser-cut hypotubes are increasingly utilized in interventional devices due to the added strength, flexibility, and kink resistance they can provide compared to traditional braided or coiled shafts. However, manufacturing hypotube assemblies can introduce additional time and process complexity, particularly when integrating liners within the inner diameter (ID) of the hypotube.

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. The new mandrel technology helps support more consistent assembly processes while reducing reliance on pressurized systems or other complex techniques to place and secure the liner against the inner walls of the hypotube.

“Constructing hypotube assemblies often requires extremely tight tolerances between the liner OD and the hypotube ID, along with complex techniques to secure the liner,” said Suresh Sainath, Chief Technology Officer at Zeus. “XpanCore was developed to help simplify that process by expanding gently and helping push the liner radially outward during processing, helping address common sizing, placement, and adhesion challenges, and ultimately helping speed production and improve yields.”

The new mandrels are intended to support manufacturers as catheter designs continue to evolve toward greater complexity, tighter performance requirements, and more advanced shaft constructions.

“Next-generation catheter technologies require manufacturing solutions capable of keeping pace with increasingly sophisticated device designs,” said Mike Evers, Director of Commercial Marketing at Zeus. “With XpanCore, device manufacturers now have access to a new processing approach that can help simplify assembly, support repeatability and improved yields, and expand design flexibility across a wide range of advanced catheter applications.”

QUICK FACTS

• Zeus developed XpanCore mandrels to help simplify the construction of hypotube assemblies and other complex catheter systems.
• XpanCore mandrels are engineered to expand outward when heat is applied to help secure liners during construction.
• The new mandrel technology helps address liner sizing, placement, and adhesion challenges.
• XpanCore mandrels are available in FEP and PFA.

RESOURCES

XpanCore™ Mandrels: Click here to learn more and request a sample.

Zeus: Learn more about the company and its products on the Zeus website or call toll-free at 1-800-526-3842 or +1-803-268-9500 outside the U.S.

ABOUT ZEUS

Zeus, headquartered in Orangeburg, South Carolina, is a global leader in advanced polymer solutions that help accelerate innovation across medical, aerospace, energy, automotive, fiber optics, and other demanding markets. Since 1966, Zeus has helped customers solve complex engineering and manufacturing challenges with advanced materials expertise and precision manufacturing. Through its CathX Medical business, Zeus also provides catheter design support and manufacturing services that help customers bring new technologies to market faster. Zeus operates a network of manufacturing facilities across the United States and Ireland. For more information, visit www.zeusinc.com.