Wire and tube forming is an integral part of the medical device manufacturing industry. With the need for smaller and less invasive devices, customers have relied on Tegra Medical for years for custom wire and tube forming: bending, swaging, flaring, coining, and Nitinol heat setting.

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Wire and Tube Bending

Wire and Tube Bending

Tegra Medical uses a wide array of equipment and methods to meet your specifications and volume requirements for wire and tube bending. No job is too big or too small. If all you need is a low volume prototype, we’ll use our manual tools. When your needs grow, we’ve got automated pneumatic and/or servo driven bend tools designed and constructed in-house, and ready to meet all your high-capacity requirements.

Tube Swaging

Tegra Medical uses a cold working process to reduce tubing diameters or completely close ends. Tubing is forced through a set of machined dies and cold worked into the desired shape or diameters. A 30-percent size reduction is typical, with up to a 50-percent reduction possible depending on the tubing gauge. The wall thickness will increase where the swaging occurs.

Tube Flaring

Flaring is another cold working process; it’s quicker than swaging. The general rule of flaring is that the flared OD can be as large as 1.4 times the starting tube OD, otherwise the tubing may split. Flaring is either a one-off operation or semi-automatic, depending on the requirements of the product. An extension of flaring would be tubing expansion. This process is very similar and is used to expand the OD of the tube rather than create an angle.

Wire and Tube Coining

Coining uses custom developed tooling and dies with the aid of a power press to accurately coin (flatten) tubing or wire. Angles or radii can be achieved in corners of a coined part through tooling design.

Nitinol Wire and Tube Heat Setting

Nitinol wires or tubes are forced into the desired shape and baked at 500-800°C for various times depending upon the size. The component will remain in the set shape after treatment.

We take great care to ensure that the final product is super elastic above 20° C. Shape memory applications typically require transformation at body temperature. For these applications, the Nitinol form is quenched in liquid nitrogen to make it soft and usually assembled in a catheter or endoscope. Once the component is deployed into the body, it springs back to its heat set shape.

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