In today’s medical device industry, performance, precision, and reliability are non-negotiable—especially when it comes to minimally invasive technologies like catheters and scope devices. Behind the scenes of these life-saving tools is a critical component that often goes unnoticed: precision flat and shaped wire.
At United Wire Company, flat, rectangular, and custom-shaped wire play an essential role in supporting braided medical applications, helping manufacturers achieve tighter tolerances, improved performance, and consistent results.
Why Braided Wire Matters in Medical Devices
Braiding is widely used in medical devices to enhance:
- Torque transmission for precise control
- Pushability and flexibility in long, narrow devices
- Kink resistance without sacrificing softness
- Structural integrity in thin-wall designs
Catheters, endoscopes, and other scope-based devices rely on braided reinforcement layers to perform reliably inside the human body. The geometry of the wire used in those braids has a direct impact on how the device behaves.
The Advantage of Flat and Shaped Wire in Braiding Applications
Unlike traditional round wire, flat and shaped wire offers distinct mechanical and design advantages when used in medical braiding.
- Improved Coverage with Less Material
Flat and rectangular wire provides greater surface contact within a braid, allowing manufacturers to achieve higher coverage and strength using less material. This can help reduce overall device diameter—critical for minimally invasive procedures.
- Enhanced Control
Shaped wire improves torque response by creating more consistent engagement within the braid structure. For catheter and scope devices, this translates into better physician control and responsiveness during procedures.
- Consistent, Predictable Performance
Precision-drawn shaped wire maintains tight dimensional tolerances, which is essential for producing uniform braids and repeatable device performance—especially in high-volume medical manufacturing.
- Optimized Flexibility and Kink Resistance
By adjusting wire geometry, engineers can fine-tune the balance between flexibility and strength. Flat and shaped wire allows designers to optimize bend behavior while minimizing the risk of kinking or collapse.
Applications in Catheters and Scope Devices
Flat and shaped wire is commonly used in:
- Diagnostic and interventional catheters
- Guide catheters and delivery systems
- Endoscopic and laparoscopic scopes
- Pull wires and control elements
In braided catheter shafts, shaped wire supports thin-wall designs while maintaining the mechanical performance required for navigation through complex anatomy. In scope devices, it helps deliver reliable articulation and torque control in compact assemblies.
Precision Matters: United Wire’s Capabilities
United Wire Company specializes in producing ultra-precision flat, rectangular, and custom-shaped wire for medical applications. With decades of experience and in-house shaping expertise, United Wire can manufacture:
- Flat and rectangular wire down to extremely fine dimensions
- Tight-tolerance shaped wire for medical braiding
- Consistent, repeatable wire profiles for demanding applications
For medical OEMs and braiders, this level of precision helps reduce downstream variability, improve yields, and accelerate product development.
Supporting Innovation in Medical Device Design
As medical devices continue to become smaller, more complex, and more performance-driven, material selection becomes increasingly critical. Flat and shaped wire enables designers to push boundaries—delivering devices that are stronger, thinner, and more responsive.
United Wire partners with medical manufacturers early in the design process to help identify the right wire geometry for each application, supporting both R&D and full-scale production.
Learn More:
To learn more about United Wire’s medical wire capabilities or to discuss a braiding application, contact our team directly at sales@unitedwirecompany.comm
Precision wire. Built for performance. Trusted in medical applications.