TE Connectivity Uses 3D Printing to Cut Catheter Manufacturing Costs

The process

TE Connectivity's Advanced Technology Group in Galway, Ireland, developed a new way to build catheter shafts. Instead of extruding a polymer jacket separately and sliding it over the core, the team prints the polymer directly onto the rotating catheter shaft in place. The result uses less material, cuts production time, and keeps part properties consistent.

Catheters are tricky because every section can require a different thickness, length, or material. Traditional manufacturing often involves multiple steps and hand assembly. TE's in-house process lets the team iterate faster and embed features directly into the layers, such as sensors, conductive traces, or different durometers for specific sections.

Why it matters

This is not a research project. TE has been using 3D printing since 1987 and has the institutional depth to turn prototypes into production processes. The company already uses additive manufacturing for connectors, seals, and even a 3D printed motorcycle. Catheter manufacturing is a natural extension of that expertise.

The medical device market is cost-sensitive. Catheters can be disposable or reusable, and they range from simple urinary catheters to complex electrophysiology tools. Any process that lowers cost without sacrificing performance gets attention from procurement teams.

TE's team sees wider applications beyond catheters. The same approach could coat other medical devices, apply biocompatible substances, or deposit wound-healing materials. The company's long view of 3D printing gives it an advantage in turning these experiments into repeatable manufacturing.