The Advantages of Microlayer Technology

Microlayer technology represents a significant advancement in the design and manufacturing of medical tubing and catheter components. By enabling ultra-thin, highly controlled coating layers, Microlayer solutions provide unmatched precision, flexibility, and design freedom addressing many of the limitations found in conventional extrusion practices.

Smooth, Controlled Transitions

One of the key advantages of Microlayer technology is its ability to create seamless, gradual transitions between components. With ultra-thin layers measuring as little as 0.00001 inches, Microlayer eliminates abrupt joints and rigid interfaces, resulting in smoother catheter insertion, improved mechanical integrity, and enhanced user experience during clinical procedures.

Optimized Diameter-to-Wall Thickness Ratio

Achieving large inner diameters with minimal wall thickness is a persistent challenge in catheter and tubing design. Microlayer technology makes it possible to produce polymer tubes with a minimum diameter of 0.0118 inches and wall thicknesses as low as 0.001 inches. This performance exceeds standard extrusion capabilities, allowing for improved flow, reduced profile, and better device deliverability.

Tight Tolerances That Matter

Consistent quality depends on precise control of wall thickness and dimensional tolerances. Medibrane’s Microlayer coating technology enables wall thicknesses of 0.001 inches with tolerances of ±0.0002 inches, ensuring uniform performance across production batches. Such precision is critical for maintaining mechanical reliability and predictable behavior in complex anatomical pathways.

Design Freedom Across the Shaft

Microlayer technology supports multiple durometers and variable wall thicknesses along a single shaft. Through surface activation techniques, it enables strong, durable connections while preserving flexibility where it is needed most. This level of customization provides engineers with unprecedented freedom to tailor device performance to specific clinical and industrial requirements.

Softness That Improves Performance

Softness plays a crucial role in patient comfort and device flexibility. Microlayer technology makes it possible to achieve low durometers—down to 40A—while maintaining thin walls. Additionally, the use of extended TPU membranes enables reliable bonding to ePTFE membranes, delivering enhanced flexibility and comfort compared to conventional designs that typically rely on stiffer 80A materials.

Microlayer technology is not just an incremental improvement it is a platform for next-generation medical device design. By combining precision, flexibility, and advanced material integration, it enables innovative solutions that push beyond traditional manufacturing limitations.