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There is a growing demand for very small surgical needles in surgical procedures. At the very extreme are, for example, surgical needles for cosmetic and ophthalmic operations. These stainless steel needles are eyeless and usually have a diameter of less than 160 μm. In order to attach a surgical thread to such a needle, a so-called blind hole must be drilled in the end of the needle. The blind hole is usually ≥ 50 μm in diameter and has a precise depth-to-diameter ratio. In the past, mechanical drilling was the only solution to this problem. However, mechanical drilling is slow, requires frequent drill bit changes and cannot drill diameters < 300 μm. Would it be possible to use a laser to drill such small holes in metal? Yes, laser drilling is a possible way.
Solution
Coherent's NA200 and NA502 are special laser drilling systems that provide an ideal solution, specifically optimized for laser drilling holes in traditional and micro surgical needles. The laser can drill holes in the diameter range of 50 - 750 μm with aspect ratios up to 6:1. Only one laser pulse is used to drill each hole, meaning up to four needles per second can be drilled in virtually any type of medical stainless steel. The long pulses delivered by the laser source are precisely shaped to drill holes smoothly and without unwanted thermal damage to the material.
The Coherent NA range of laser "drills" are built on an ultra-stable granite table. The machines feature extremely high laser beam stability and pulse repeatability. Precise control of the energy, shape and duration of the laser pulse results in drilling holes with consistent diameter and depth, as opposed to mechanical drilling which negatively affects actual tool wear. The consistency of production also ensures high yields in the subsequent crimping process for attaching the surgical wire or thread to the needle.
Coherent NA laser drilling systems are optionally equipped with a second "rounding" laser, which is used to create a smooth spherical hole mouth, simplifying the eventual drilling of threads. For high-volume production, Coherent has designed a complete system including automatic feeding and handling with external suppliers.
Advantages of laser drilling
Coherent's NA200 and NA502 laser drilling systems enable high-volume production of surgical needles at low production costs. Laser-drilled holes feature smooth edges, minimal thermal damage to the material and excellent consistency between products.
High volume laser drilling of surgical needles
Coherent's NA200 and NA502 laser drilling systems enable high-volume production of surgical needles at low production costs. Laser drilling is fast and does not produce unwanted burrs and splinters, eliminating the subsequent technological operations of deburring or cleaning the drilled hole. You can see the high productivity of the Coherent NA 302 laser drilling system in the following video.
