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Alloys made of aluminum that are cheap to use in various applications. As aluminum is lightweight and offers good thermal and electrical conductivity. Medical it is, therefore, not surprising that people are utilizing them more frequently in the production of commodities. For instance, it is common in consumer goods packaging, packaging for batteries and electronics, and automotive components. It offers a surface oxide layer, high reflectivity, and volatile alloying components, which are the three main reasons why laser welding aluminum is more challenging than welding steel.

You need to have Medical high power density to overcome aluminum’s high reflectivity. Also, it enables the laser to heat the part because aluminum is very reflective to 1064 or 1070 nm wavelength. Surface oxide layer removal guarantees that you can remove any dirt or impurities that may be present in the oxide layer. Whether it is to complete mechanically or chemically, keep in mind that you should never use plating near where you weld. This is because it frequently results in weld cracking.

In order to prevent the more flammable alloying components that might lead to excessive porosity and cracking; however, it is important to use the right material. Typical suitable material selections are 1050, 2219, 3003, 5052, 6061, and 4047. Because the 4047 alloy contains silicon, which inhibits cracking, 6061 can only be welded in conjunction with 4047, but you can use 4043. 

Welding of RF/Microwave Packages Hermetically

For the body and lid, respectively, the necessary material combinations are 6061 and 4047. In addition, you should join the geometry to reduce the amount of penetration needed. A 500- or 600-micron spot size is typically important in these applications. This is to provide joint coverage and weld stability. 

In this following article, we are going to discuss some of the popular medical devices using lasers. We will be discussing the top four applications of industrial lasers in the production of medical devices, along with the laser sources that are most suited to each application.

The Top 4 Medical Devices Using Lasers

Lasers are the true Swiss Army Knives of manufacturing; they are commonly used for a wide variety of medical device production procedures. This includes labeling, micro-welding, cutting, micromachining, and more. 

1. Laser Welding is Perfect for Combining Incredibly Small, Complex Pieces

Seam welding, Spot welding, and hermetic sealing of small, complex medical equipment frequently involve the utilization of lasers. A weld with penetration and weld breadth of less than 1 mm is a laser micro weld. For pacemakers, endoscopic equipment, surgical blades, and batteries, micro welds like this are common to use.

2. Precision Laser Cutting for Cannulas, Shafts, Hypo Tubes, and Razor Blades

Arthroscopic razor blades, flexible shafts, stents, cannulas, and hypo tubes can all be cut with a laser, but hypodermic needles cannot.

There are typically two ways to cut with lasers:

  • Gas assistance cutting is frequently usual with a microsecond laser source.
  • Ablation is a procedure that commonly uses a nanosecond, picosecond, or femtosecond laser source. This is to fire on the part with immediate material ejection; no post-processing is necessary, and there is a small heat zone.
  • The most typical technique for laser cutting medical equipment is gas-assisted cutting. You can get an excellent cut-quality width with enough speed and precision. The need to switch to an ablative approach using quality lasers arises as the tube diameter and feature sizes decrease. 
  • This method may produce features with kerf widths and diameters on the order of tens of microns.

3. Laser Marking is Excellent for the Trackability of Products

Numerous medical and dental devices, such as bone screws, cases that store delicate electronics like pacemakers. Also, you can mark the auditory implants and endoscopic tools with lasers. Laser marking is a direct part marking (DPM) method that is popular for being an effective way to permanently identify business and product/part information. This is to ensure traceability and is perfect for obtaining corrosion resistance. Also, a unique device identifier (UDI) mark is necessary by the FDA.

Moreover, there are various laser sources, as per wavelength, laser medium, or pulse duration, that are appropriate for laser marking. These include picosecond, femtosecond, and ultrashort pulse (USP), far infrared (FIR), infrared (IR), green, and ultraviolet (UV) lasers. You can determine the project’s optimal laser source by the material you choose. 

4. Accurate Hole Drilling and Surface Sculpting with Laser Micromachining

To surface texture and drill holes in needles, implanted devices, catheters, and micro instruments, medical device manufacturers utilize laser micromachining. Ultra-short pulse (USP) lasers are frequently commonly used in these applications. Due to the reason the short pulse duration makes it possible to remove the material. This happens much more effectively and with less energy input into the part. 

In addition, it produces clean cuts with less post-processing as the user’s demand. Laser micromachining, while not particularly quick, is incredibly accurate. This makes it a particularly attractive option for surface texturing of polymer catheter tubes. A femtosecond pulsed laser provides the exact texture depth control. Also, these are very reliable structures necessary for this application.


Lasers work effectively in a range of procedures for producing medical equipment. Although each procedure calls for a unique laser source, you may get the best option. If you are looking for aluminum products and services, Aluminum alloy parts anodizing service provider is here to offer you FREE quotes. Moreover, for laser-related products, Uga Aluminum is available to test your samples. Also, our team offers suggestions on the best laser to use and other helpful information. You may get the best product at the best affordable products. 


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