Advanced Nitinol Braiding Platform for Complex and Hybrid Structures

Recent progress in minimally invasive and shape-memory applications has increased the demand for nitinol braids with more versatile and functionally differentiated architectures. Conventional braiders are limited by fixed carrier paths and uniform strand behaviour, constraining the range of achievable geometries and material combinations. This work presents a new braiding platform developed to extend the design space for superelastic and hybrid structures.

The system enables independent control of each wire carrier, allowing local variation in braid density, pattern, and strand composition. Fully automated tension control maintains consistent mechanical conditions throughout production without operator intervention. The platform can produce a wide variety of configurations including side-hole braids, partial splits, bundled regions, and flat sections within a continuous structure. It also allows mixing of materials such as nitinol and polymer filaments or combining wires of different diameters within the same braid.

These capabilities open new opportunities for the design of advanced medical and actuation devices, particularly those integrating braided and laser-cut features into a single construct. Early results demonstrate high reproducibility, minimal setup time, and precise control of strand positioning, enabling prototypes that could not previously be achieved using traditional braiding methods.

This technology provides a flexible manufacturing route for next-generation superelastic components and hybrid implants, supporting innovation in endovascular, neurovascular, and soft robotic applications.