The medical device industry continues to evolve at a breathtaking pace, driven by advances in materials science, engineering, and manufacturing technologies. As we look ahead to 2025, four key trends stand out, shaping the future of medical device manufacturing. From innovative materials to sustainable and cost-effective production, here’s a closer look at what’s next.
- Advanced Materials for Nitinol Components
The development of stents has always been at the forefront of medical device innovation. Advanced materials are pushing the boundaries of what stents and other Nitinol-based components can achieve in terms of flexibility, fatigue resistance, and durability.
Confluent’s SE508 ELI material is a high-purity Nitinol ideal for high-cycle fatigue applications such as cardiovascular implants or components with small features such as neurovascular stents. The growing demand for minimally invasive procedures means devices will continue to get smaller and are indicted for increasingly challenging anatomy. The ability to manufacture high-purity Nitinol material in the form of wire, tubing, and sheets with small nominal dimensions and tight tolerance will be a continuing theme going forward. - NMP-Free Polyimide for Safer Manufacturing
N-methyl-2-pyrrolidone (NMP) is a commonly used solvent in polyimide manufacturing but has been flagged by the EPA for its environmental and health risks. In response, the industry is transitioning to NMP-free alternatives.
To mitigate a potential risk to the industry’s supply chain, Confluent has developed an NMP-free option with equivalent performance to historical polyimide along with a stable supply chain. This material meets Europe’s REACH compliance requirements, avoids the impending EPA findings against NMP, and provides improved safety for our employees, vendors, and patients. - Biomaterials for Advanced Healing
Biomaterials are redefining what’s possible in patient recovery and device integration. These materials are designed to promote rapid healing while minimizing complications such as inflammation or infection.
Confluent recently added a new Biomaterials Manufacturing Center at its textiles manufacturing location. This expansion enables Confluent to combine its textile expertise with these new material technologies, offering novel textile solutions that promise improved patient outcomes.
Biomaterials such as decellularized collagen have an exciting future for the rapid healing of implantable devices. These materials often provide an extracellular matrix and cellular cues to promote tissue regeneration and healing. Bioinductive scaffolds may reduce healing time and improve success rates in sports medicine applications. For cardiovascular and structural heart devices, the benefits of biomaterials may include quickly driving tissue integration to stabilize an implant, heal a wound, or generate an anti-thrombotic surface. - Low-Cost Manufacturing
Cost-effective manufacturing remains a priority in the medical device industry, and Costa Rica is emerging as a key player. Our facilities in Costa Rica are the heart of our manufacturing, leveraging industry knowledge, lean manufacturing principles, and a skilled local workforce.
In 2022, Confluent added 66,000 square feet of manufacturing to the Costa Rica facilities greatly expanding the capacity to process Nitinol components and produce complex catheters using a combination of clean rooms and white-space manufacturing.
By situating operations in Costa Rica, we’re not only reducing production costs but also ensuring compliance with international quality standards. This strategic approach enables us to pass on savings to our customers without compromising the performance or reliability of our components.
The future of medical device manufacturing is brighter than ever, driven by groundbreaking advances in materials, innovative design approaches, and sustainable manufacturing practices. As we step into 2025, these trends will shape the next generation of medical devices, bringing better outcomes for patients around the world.