Real-Time Laser-Cutting Monitoring for Enhanced Quality in Nitinol Stent and hypotubes manufacturing

The manufacturing of medical devices demands exceptional precision due to the material’s unique properties and the critical nature of its medical applications. As a provider of advanced laser tube cutting systems, we introduce a real-time monitoring solution designed to ensure cutting quality and process reliability.

Our system captures and processes key signals reflected during laser cutting—plasma, temperature, and laser back-reflection. These signals provide immediate insight into the cutting process, by correlating signal patterns with cutting outcomes.

Experimental validation was conducted on nitinol tubes under varying process parameters using fiber laser and femtosecond laser sources. Signals belonging to parts with errors were compared with good parts data, demonstrating high sensitivity and specificity in error detection, enabling recognition of anomalies such as incomplete cuts, defocusing, and misalignment.

This data-driven approach supports early error detection, reduces scrap, and enhances traceability—key factors in meeting stringent medical device manufacturing standards. Furthermore, the system lays the foundation for closed-loop control and predictive maintenance, contributing to higher throughput and reduced downtime.

We will present the system architecture, signal acquisition methodology, and validation results from nitinol cutting trials. The findings demonstrate how real-time monitoring can elevate quality assurance and process control, ultimately supporting the reliable production of complex stent geometries.