Automated medical device manufacturing is the foundation of consistency and scale when it comes to passing stringent medical trials, but one component often overlooked in the design phase is the wire form. These intricate, high-precision components need to be optimised for automation or otherwise risk slowing down production and driving up scrap rates.
Engineers need a solid understanding of why and how wire forms should be designed and packaged for compatibility with automated and semi-automated assembly lines. Only then can scrap rates be reduced and manufacturing efficiency be achieved.
Automated medical device assembly lines rely on repeatable and efficient component handling. Wire forms that aren’t designed with automation in mind can bring issues like misalignment, entanglement, deformation or machine stoppages. These setbacks reduce throughput, increase costs, and in some cases, compromise the device’s compliance with international standards.
Adopting a “Design for Pharmaceutical Manufacture” (DfPM) approach helps mitigate these issues. DfPM emphasises the functionality of the wire form and how it interacts with manufacturing equipment and packaging solutions throughout the entire production lifecycle.
Designing wire forms for use in automated medical device assembly lines involves more than just achieving the correct shape or function. Several critical factors must be addressed early in the design process to ensure these components integrate seamlessly with high-speed, precision-driven manufacturing environments. Below are some of the most important considerations.
Medical wire forms need to be produced with extremely tight tolerances to ensure consistent pick-and-place operations along with seamless integration with other device components. Any variability in form, fit or function can lead to misfeeds or misalignment during automated insertion which is exacerbated in high-speed assembly environments. Selecting high-grade materials (304 stainless steel, nitronic) can help improve dimensional stability during forming to help reduce post-processing deformation risks.
Poor surface finish or sharp edges can lead to snagging, higher wear on feeding mechanisms or even particulate shedding which is an unacceptable risk in sterile medical environments. To protect against these issues, techniques like laser deburring and vibratory finishing are essential for smoothing surfaces without damaging the wire form’s structural integrity.
Materials such as 302 or hard stainless steel offer a balance between spring-back resistance and formability, making them ideal for static wire forms used in repeatable automated processes. For more complex, high-stress applications, nitronic materials provide greater ductility and corrosion resistance which are essential for longevity and process repeatability.
Even if wire forms are precision-engineered, improper packaging can undermine their automation potential. Entanglement during unpacking or feeding disrupts automated lines and necessitates manual intervention. Solutions like reel-based packaging for continuous feeding and blister trays for delicate geometries are essential to protect both components and overall efficiency.
Packaging must also consider post-sterilisation processes. Certain plastics or coatings used in packaging may affect sterility or introduce particulates, so packaging selection must be harmonised with the entire device sterilisation and assembly journey.
Working with a specialist manufacturer who understands both the regulatory pressures and the technical demands of automated assembly is invaluable for reducing rejection rates and enhancing efficiency. A trusted partner has access to/knowledge of dedicated medical-grade machinery and the right steps to take to ensure complete automation.
As automation becomes an industry norm rather than a differentiator, medical device designers need to ensure components are designed and prepared for high-speed, high-volume assembly lines. The intersection of engineering precision, material science, and packaging innovation is where successful, scalable medical manufacturing happens.
At Advanex Medical, our wire forms are produced using dedicated medical-grade machinery to the tightest tolerances of any mass manufacturer. We provide expert guidance in wire form development and automation-ready component supply to help reduce costly redesigns, minimise scrap rates and accelerate time to market.
Download our guide below to find out more about design for pharmaceutical manufacturing processes and how they enhance efficiency.