Fine laser cutting is an ideal technology for specialized cutting requirements found in the manufacturing of medical tube tools and components. From surgical instruments used in cutting and biopsy, to needles containing unusual tips and side wall openings, to puzzle chain linkages for flexible endoscopes, laser cutting provides higher precision, quality, and speed than traditionally used cutting techniques. In addition, new laser cutting technologies are now coming to market, including a 5-axis motion package that gives the designer freedom to cut more challenging geometries in one pass.

A key to successfully using the technology is properly integrating the system’s components into a process flow that works. The motion, laser, software, and tooling must all work together to achieve the desired results.

Laser Cutting Benefits

Laser cutting is ideal for working on small tubes that must be cut to high dimensional accuracy because the laser light used does not have any physical presence and makes no contact with the material. It does not push, drag, or impart force that might bend a part or cause flex that would have a negative impact on process control.

It also offers minimal thermal input, with fine control over how hot the work area gets. This is important since small parts heat up quickly and might otherwise overheat or deform.

Laser cutting is highly focusable to about 25 microns, which is about 1⁄4 of the width of a strand of human hair. This makes it feasible to remove the minimum amount of material to make the cut, resulting in extremely high precision and high accuracy.

The laser cutting technology has an extremely fine control of pulse width, power, and focus spot size. Because the laser cutting tool does not rely on touching the part, it can be oriented to make any shape or form. Not limited by physical cutting geometry, laser cutting can be used to make unique shapes.

Laser Cutting for Medical Tools

Figure 1 - Fiber laser cutter with gas assist
The technology frequently used to make medical tubes and components is fiber laser cutting with gas assist. This means that the laser is “assisted” with a coaxial gas, typically oxygen (O2). While O2 is usually the gas of choice, occasionally shop air can be used after oil filtering, usually when the tube thickness is less than 0.01-inch, or when the cut quality required is not very high. This technology is used for stainless steels (300 and 400 series, 17-4, 17-7); MP35N (cobalt-chrome steel alloy); and Nitinol. The method can be used for both on-axis (90° to surface) and off-axis (angled to surface) cutting.

A highly focused laser is used to melt a thin sliver of material. While the material is still molten, a 0.02-inch diameter gas jet nozzle that is coaxial with the laser blows away the molten material. The desired features are produced using this continual cycle of melt, then melt ejection. Distance between the laser and the material needs to be maintained precisely.

The O2 actually serves two purposes — it blows away the molten material and also serves as a heating element, because the heated material reacts with it and heats up. The heat reaction caused by the presence of O2 adds about 30 to 50 percent more heating energy to the cutting area. Figure 1 illustrates a basic fiber laser cutter with gas assist.

Laser cutting with gas assist produces the highest cut quality and high resolution cut paths, a key focus of makers of medical tube tools and components. Dimensional accuracy is key to measuring cut quality — does the part match the print? Other considerations include surface roughness (better than 12 micro inches) and the absence of thermal damage.

Cut width can be extremely small with laser cutting — less than 0.001-inch — and dimensional accuracy is extremely precise, at about +/- 0.0005-inch. This accuracy is very useful for producing the jagged teeth used in some cutting tools. Dross or burr left on the underside of the cut (which can become attached and resolidified) is minimized or eliminated. This significantly reduces the amount of post-processing needed. The recast level layer (a small amount of material that doesn’t get blown away during the process) is less than 0.0005-inch.

Figure 2 illustrates the typical cut quality with no post processing of features and edges when cutting .01-inch thick stainless steel (304SS) tubing, showing the excellent quality of laser cut faces.

Photonics Tech Briefs Magazine

This article first appeared in the October, 2011 issue of Photonics Tech Briefs Magazine.

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