Manufacturing Capabilities

MANUFACTURING NEXT-GENERATION MEDICAL DEVICES

Two men in work uniforms operate and monitor a Hanwha XD16II industrial machine in a factory setting.

TECHNOLOGY AND EXPERTISE TO ENSURE YOUR SUCCESS

We apply our extensive manufacturing capabilities to deliver precision solutions with excellence. We combine tailored development services with high quality, cost-effective manufacturing processes to ensure your project success.

Icon of a laser tool with text: "Laser Technology—photonic systems for cutting, welding, marking, sintering, and abrading.
Icon of a laser tool with text: "Laser Technology—photonic systems for cutting, welding, marking, sintering, and abrading.
Icon of a drill with text: Micro-machining, EDM technology, micro-laser-cutting, hi-speed turning and milling.
Icon of a drill with text: Micro-machining, EDM technology, micro-laser-cutting, hi-speed turning and milling.
Icon of a grinding tool with text: "Grinding technologies from standard bevel grinds to specialized designs.
Icon of a grinding tool with text: "Grinding technologies from standard bevel grinds to specialized designs.
Icon of an injection molding machine with text: "Insert Molding—technique integrating pre-formed components.
Icon of an injection molding machine with text: "Insert Molding—technique integrating pre-formed components.
Icon of a forming tool and text stating: "PRECISION FORMING: Mass production of complex components with micron-level accuracy
Icon of a forming tool and text stating: "PRECISION FORMING: Mass production of complex components with micron-level accuracy..png
Icon of injection molding machine next to text: "INJECTION MOLDING: Precision parts made by injecting, cooling, and molding materials.
Icon of injection molding machine next to text: "INJECTION MOLDING: Precision parts made by injecting, cooling, and molding materials.
Icon of a hand under a faucet next to text reading “Cleanroom Assembly: Manual and automated assembly of delivery systems and instrumentation.”.
Icon of a hand under a faucet next to text reading “Cleanroom Assembly: Manual and automated assembly of delivery systems and instrumentation.”.
Icon and text stating: "METAL FINISHING: Enhances surface properties, functionality, and biocompatibility.
Icon and text stating: "METAL FINISHING: Enhances surface properties, functionality, and biocompatibility.

LASER TECHNOLOGY

Our temperature-controlled Laser Technology Center employs
high-volume production equipment and purpose-built systems to meet your component requirements. We laser cut features in tube from 0.2 mm to 20 mm, and our minimum kerf width of 0.012 mm enables us to meet your component design needs.

  • 4-axis tube laser cutting, providing off-axis profiles on four separate systems

  • High-precision, flat-bed micro-laser cutting

  • Micro-laser welding, including automated welding systems (0.1mm spot size)

  • Laser marking on metal or plastic with distinct matte black finish

  • Laser cutting on stainless steel and Nitinol

  • Laser ablation providing engraved surface text, features or mold keys

Close-up of an automated industrial machine with wires, metal parts, and sensors on a manufacturing production line.
Close-up of an industrial machine with pointed metal needles under a warning sign, illuminated by a small light.

MICRO-MACHINING

Elevaris Medical operates full 4D design and machine programming systems. We can interpret customer requirements via drawings or computer models, and quickly establish feasibility and delivery plans.

We utilize proprietary combination of laser technology, EDM wire erosion and sink erosion, 5-axis CNC machining and 3D Metal Printing Technology to ensure we can uniquely meet our customers’ high expectations in component manufacturing.

A metal lathe spinning at high speed while shaping a small cylindrical workpiece in the center.

GRINDING

Our engineers use grinding technologies from standard bevel grinds to specialized designs like those needed for trocar or micro needles. Count on us for these grinding methods and tip styles:

  • Centerless grinding for precision solutions

  • Computer Numerical Control grinding for precise, repeatable grinding of complex needle tip geometries

  • Electrochemical grinding, which allows for highly precise and burr-free tip grinding

  • Standard Bevel and A&B Bevel grinds

  • Lancet points, suitable for precise cutting and sampling

  • Trocar grinds, designed for creating access points in minimally invasive procedures

  • Diamond points, durable, multi-faceted tips

  • Micro needles, often used for diagnostics and drug delivery

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INJECTION MOLDING

Injection molding is a manufacturing process where molten material is injected into a mold cavity, where it cools and solidifies, creating a part with the desired shape. This process is commonly used for plastics, but can also be used for other materials like metals and glasses. The process involves several key steps: clamping the mold, injecting the molten material, holding pressure, cooling, opening the mold, and ejecting the part. 

A machine fills multiple syringes with yellow caps, aligned in a row for automated processing in a laboratory setting.
A person in a lab coat adjusts purple plastic components on an industrial metal mold in a manufacturing setting.

INSERT MOLDING

Insert molding is a specialized injection molding technique that integrates pre-formed components, often metal inserts, into a plastic part during the molding process. Molten plastic is injected into a mold containing the insert, bonding it to the plastic and creating a single, integrated component. This process enhances durability, functionality, and can reduce assembly steps.

A person in a lab coat and hairnet works at a table with a magnifying lamp in a laboratory setting.

CLEANROOM ASSEMBLY

We have world class cleanroom assembly areas in both our manufacturing locations.

Our ISO Class 7 and Class 8 cleanroom assembly areas have been developed for a number of specific customer products. This has provided a wide range of assembly capabilities, from packaged needles to hypo-tube catheter delivery systems.

We can support both development and production volumes.

Cleanroom assembly capabilities consist of:

  • Metal and polymer component cleanroom sub-assembly

  • UV and air-cured adhesive bonding

  • Automated heat shrinking with FEP & PET tube

  • PTFE tube inner liner installation

  • Automation - hi-speed assembly and inspection

  • Packaging and pouching

  • Testing and qualification

  • The Elevaris Product Assembly Group carefully designs and manufactures each component to meet stringent quality standards. We also offer quick turnaround times with our assembly and packaging services to make the process easier for you.

    Our highly efficient and automated assembly capability, with fully validated packaging processes, is available for companies looking for contracted packaging solutions to market their products as quickly and easily as possible.

    We also offer an array of packaging, private-label, and EtO sterilization options to meet your needs.

    For low-volume operations, our team can hand pack your product into Tyvek® pouches that we then can label and sterilize.

    Our state-of-the-art MULTIVAC packaging solution is a great option for high-volume components or finished goods. We can configure our MULTIVAC to incorporate Tyvek or paper, depending on your sterilization process objectives. Both options ensure that your product coding and marking is compliant with UDI requirements for traceability.

A person operates a milling machine in an industrial workshop under bright overhead lights.

PRECISION FORMING

Precision forming is a cornerstone process in medical device manufacturing, enabling the mass production of complex, high-strength components with micron-level accuracy. We know that performance, reliability and compliance are non-negotiable, so we use precision forming in:

  • Swaging for reduction and pointing

  • Bending and shaping

  • Pressing and flattening

A person wearing a mask and gloves operates machinery in an industrial setting.

METAL FINISHING

Metal finishing enhances surface properties, functionality, and biocompatibility and plays a vital role in ensuring that metal parts meet strict medical standards for performance, cleanliness, and safety. We use metal finishing in the following processes:

  • Electropolishing

  • Chemical Etching

  • Passivation

  • Siliconization

  • Chrome plating

A metallic silver check mark symbol on a transparent blue background.

EXTENSIVE MANUFACTURING CAPABILITIES, PRECISION SOLUTIONS