Medical Flexible Printed Circuits
The Medical and MediTech industry is constantly evolving, driving improvements in health outcomes and longevity. Amphenol Trackwise plays a crucial role in this progress through our Improved Harness Technology™ (IHT), which contributes to groundbreaking catheter-based distal electronic advancements globally.
IHT, our patented manufacturing process, enables the production of ultra-long flexible printed circuits (FPCs) and ultra-finely etched single- and multilayer flex circuits using various biocompatible materials. This technology offers significant advantages for medical applications:
- Length-unlimited FPCs, ideal for catheters of 1.1m or more
- Ultra-fine etching capabilities, with traces as fine as 50μm
- Multilayer designs for complex circuitry in compact spaces
- Biocompatible materials suitable for medical use
These features make IHT particularly valuable for minimally invasive surgical instruments, cardiac procedures, and other medical devices where space and flexibility are critical. Read on to understand more about our technical capabilities.
The Ideal Medical Flex Circuits Solution
A MediTech company approached Amphenol Trackwise after seeing our Electric Vehicle case study, impressed by our expertise in flexible printed circuits (FPCs). Their project focused on the ongoing miniaturisation of electronics and increasing functionality within distal applications, particularly for catheter-based devices.
Thanks to our Improved Harness Technology™ (IHT) manufacturing process, we were ready to tackle this challenge. We adapted and evolved our process to meet their precise requirements, demonstrating our capacity for innovation and pushing to the limits of what’s possible in FPC manufacturing
Advanced FPCs are particularly suited for catheter construction. Compared to traditional wiring methods, they offer superior mechanical strength, reduced manufacturing time and costs, and enhanced functionality. Their inherent flexibility allows them to be easily integrated into catheters, streamlining production and improving performance.
Ultra-thin, high-precision, and lightweight, a single-layer FPC can feature traces as fine as 50μm or smaller. These can be produced in unlimited lengths using a roll-to-roll process, ensuring cost-effective, high-volume manufacturing.
Electrophysiology Catheter Flex Circuit Design
Amphenol Trackwise supports medical device manufacturers with advanced flexible circuit solutions for electrophysiology (EP) catheters. Modern EP procedures require catheters to transmit high volumes of diagnostic data while also delivering therapeutic energy, all within a highly compact design.
Our custom flexible printed circuits can integrate mapping electrodes, temperature sensing and power delivery into a single biocompatible circuit, helping to reduce complexity while maintaining reliable performance.
Reliable Signal Performance:
Precision-manufactured circuit traces help maintain signal quality and minimise interference, supporting accurate cardiac and neurological mapping.
Continuous Circuit Construction:
Long-length flexible circuits can be manufactured without intermediate joins along the catheter shaft, helping to maintain a consistent profile and predictable mechanical performance.
Optimised Power Handling:
Flexible circuit designs can combine power and signal transmission within the same assembly, enabling safe energy delivery while maintaining the flexibility required for minimally invasive procedures.
Minimally Invasive Surgical Instruments
The latest generation of minimally invasive surgical instruments, including endoscopes, laparoscopes and robotic-assisted surgical devices, requires increasingly compact and reliable electronic interconnect solutions. As devices become smaller and more complex, traditional wiring systems can add unnecessary bulk, weight and assembly complexity.
Amphenol Trackwise develops high-density medical flexible circuits that help device manufacturers integrate power, signal and sensing functions within compact instrument designs while maintaining the flexibility required for demanding clinical applications.
Designed for Dynamic Movement
Our flexible circuits are engineered to withstand repeated bending and articulation, making them suitable for devices that operate through tight bend radii and complex movements.
High-Density Circuit Integration:
Fine-line circuit technology enables multiple signal, power and control pathways to be integrated within a compact footprint, helping maximise the available space inside surgical instruments.
Reduced Size and Assembly Complexity:
Replacing multiple discrete wires with a single flexible circuit can simplify device assembly, reduce component count and support more compact instrument designs.
By combining reliability, flexibility and high-density circuit integration, Amphenol Trackwise helps medical device manufacturers develop advanced minimally invasive surgical systems for next-generation healthcare applications.
IHT™ – providing technology where it’s needed most
Minimally invasive surgery (MIS) and therapies are two of the fastest growing areas of medical science.
A globally growing, ageing population and increasing demand for painless treatment, reduced risk and shorter recovery times, has driven rapid growth in the development of advanced catheter and endoscope-based, real-time and electronic medical devices.
Our dedication to the medical devices sector is exemplified by our significant investments in an upgraded ISO Class 7 cleanroom and a reel-to-reel direct imaging process. These advancements enable us to meet the stringent, high-resolution requirements of modern medical devices, reinforcing our position as a trusted partner in the industry.
WHITE PAPERS
For more information regarding replacing shielded twisted pairs with flex, please visit our White Papers page to download the PDF.