top of page

Design of advanced catheters using flexible circuit boards

Abstract This article explores the evolution and application of flexible printed circuit boards (PCBs) in advanced catheter design, focusing on both thermoset and thermoplastic-based technologies. The transition from traditional wire-based designs to flexible PCBs has revolutionized catheter capabilities, enabling the integration of advanced electronics, sensors, and complex functionalities. The paper traces the history of flexible PCBs in medical devices, from early signal transmission applications to their current role in high-performance catheters. It details the advantages of thermoset-based PCBs, including customization, sensor integration, and size reduction, while also highlighting their limitations. The introduction of thermoplastic-based flexible and stretchable PCBs, particularly the e-Shaft™ technology by CathPrint AB, is presented as a significant advancement, offering enhanced design freedom and cost-efficiency. The article discusses various catheter applications, performance metrics, and pre-clinical testing results of this technology. Future developments, including the integration of thin-film sensors and hybrid processes for ultra-thin catheters, are also explored. This comprehensive review underscores the pivotal role of flexible PCBs in advancing catheter design and functionality, paving the way for improved patient outcomes and a new generation of minimally invasive medical devices


Introduction

In the rapidly evolving world of medical technology, more intelligent and smaller surgical tools are revolutionizing patient care, with one of those seeing particularly transformative advancements: catheters. Traditionally used for a wide range of diagnostic and therapeutic procedures, catheters are now benefiting from cutting-edge innovations that are revolutionizing their capabilities. Among these innovations, flexible printed circuit boards (PCBs) have emerged as a transformative technology, enabling the development of more sophisticated, thinner, and highly functional devices that push the boundaries of what was once possible. The evolution of PCBs from rigid, bulky components to flexible and even stretchable forms has paved the way for catheters that are not only thinner and more maneuverable but also capable of integrating advanced electronics, sensors, and complex functionalities. The integration of advanced sensors into medical catheters holds immense future potential for enhancing patient care and medical procedures. By incorporating sensors capable of real-time monitoring of physiological parameters such as pressure, temperature, and biochemical markers, catheters could provide continuous, precise data directly from within the body. This could revolutionize treatments like cardiac catheterization, allowing for immediate feedback on vascular flow, pressure gradients, and cardiac output, potentially reducing complications and improving outcomes in procedures like ablation or stent placement. Moreover, the development of intelligent sensors using AI could lead to catheters that not only monitor but also predict potential issues like infections or blockages, offering proactive treatment adjustments. The miniaturization and increased sensitivity of these sensors could also make less invasive procedures more effective, potentially decreasing recovery times and improving patient comfort. 2 Moreover, the recent introduction of thermoplastic-based flexible PCBs for catheters has enabled a new dimension to catheter design: cost-efficiency. These thermoplastic materials not only allow new catheter design options but also enable production at a considerably lower cost than current ring-on-wire based catheters. This reduction in manufacturing expenses could make these next-generation catheters more accessible to healthcare providers, further driving the adoption of minimally invasive procedures and improving patient outcomes.


The beginning

Flexible printed circuit boards (PCBs) have been utilized in medical devices for a considerable period. Initially, their application was primarily focused on signal transmission. An early illustration of this technology is found in the patent US 4,690,144, titled “Wireless transcutaneous electrical tissue stimulator,” filed by Medtronic in 1982 and granted in 1987. “A transcutaneous electrical tissue stimulator comprises an electrical tissue stimulation generator attachable to the human body and a remote controller therefor. A generator includes a plurality of rigid printed circuit boards having components mounted thereon, each circuit board interconnected with flexible printed circuit board and terminal means for delivery of electrical tissue stimulation to electrodes. Remote programmer comprises user controls for control of generator stimulation mode or parameters via telemetric link.” However, it was not long before flexible PCBs were also introduced as a replacement for traditional wires in catheters, specifically in those manufactured using the commonly employed ring-on-wire technology.


bottom of page