From soft and flexible to stiff and rigid, Zeus’ diverse portfolio of high-performance, thin-walled catheter liners help device engineers transform today’s impossible into tomorrow’s reality.
Built on decades of proven performance, our liner portfolio continues to expand to meet the ever-evolving design and production challenges engineers face. From designing complex devices with ultra-thin profiles, to improving production yield, Zeus will work with you to identify and deliver the right liner solution for performance, manufacturability, and scale.
With industry-leading sizing, tight tolerances, and high-performance properties, Zeus PTFE Sub-Lite-Wall™ liners are an ideal choice for a wide variety of advanced vascular catheter designs. Super-thin-walled PTFE Sub-Lite-Wall™ liners can be produced with wall thicknesses ranging from 0.001” – 0.005” (0.025 mm – 0.127 mm), tolerances as low as ± 0.0005″ (0.0127 mm), and with uniform inside and outside diameters.
Engineered as an alternative to film-cast PTFE, PFX Flex™ Sub-Lite-Wall™ is a next-gen catheter liner that delivers proven lubricity, enhanced bond strength, and expanded sterilization options – all without PFAS.1 In addition to providing PTFE-like performance, PFX Flex™ Sub-Lite-Wall™ liners offer inherent sustainability benefits, helping to deliver design freedom, manufacturing flexibility, and compliance confidence in a world moving beyond PFAS.
Download Test Report: PFX Flex vs. PTFE Catheter Liners
Taking our PTFE Sub-Lite-Wall™ liners a step further, StreamLiner™ series represents a new class of precision liners that set the standard for advanced catheter designs. Available in multiple configurations, these ultra-thin-walled liners can be produced with nominal wall thicknesses ranging from 0.0004” – 0.00075” (0.0102 mm – 0.01905 mm) and tolerances as low as ± 0.0002” (0.0051 mm).
Manufacturing steerable catheters can be challenging and time-consuming, especially when manufacturers must procure and bundle multiple individual liners into a final catheter assembly. Zeus PTFE Sub-Lite-Wall™ multi-lumen tubing helps simplify the process while eliminating multiple manufacturing steps and complex tooling by providing engineers a single, process-ready multi-lumen extrusion.
Download Test Report: Speed Up Steerable Catheter Production with PTFE Sub-Lite-Wall™ Multi-Lumen Extrusions
Zeus polyimide liners can be produced with wall thicknesses ranging from 0.0004” – 0.005” (0.0102 mm – 0.127 mm) and ID sizes ranging from 0.0045” – 0.090” (0.1143 mm – 2.286 mm), enabling them to reach the smallest vasculatures. Our polyimide liner products include PI, braid and coil reinforced PI, and PI Glide™, our high lubricity PI/PTFE composite.
For improved bonding between catheter layers, a Tie Layer coating can be applied to many Zeus liners. This ultra-thin thermoplastic coating creates a melt-bondable surface that helps improve jacket-to-liner adhesion during the reflow process, helping prevent delamination.
Download Test Report: Overcoming Catheter Failure with Tie Layer
1. PFX Flex™ Sub-Lite-Wall™ liners are made using a non-fluorinated polymer resin alternative to PTFE and without the intentional addition of any per- or polyfluoroalkyl substances (PFAS). Independent third-party laboratory analysis on representative samples of PFX Flex™ Sub-Lite-Wall™ liners has confirmed total fluorine levels of less than 20 ppm in liner samples analyzed.
2. Based on test report, comparing PFX Flex™ vs. PTFE Catheter Liners. January 2026.
Capabilities, sizing, properties, & more.
Testing the effects of tie layer on jacket-to-liner bond strength.