- Large balloon diameter (20 mm–40 mm)
- Short balloon overall length (shorter than balloon diameter)
- Small catheter size
No company had ever made a medical balloon with these ratios—Vention was breaking new ground. The team had to push the limits of technology and develop new internal processes to produce balloons that met these requirements.
The Vention team began working on prototypes for the customer’s design of 2 noncompliant balloons. However, testing revealed that the profile of 2 noncompliant balloons would be too large and too stiff.
The Vention team came up with the idea of using a compliant medical balloon of a different, more elastic material for the outer balloon. This reduced the profile and stiffness, without compromising strength and burst pressure needed for safety. The team worked closely with the customer on many iterations, often sending samples to test overnight and tweaking the design the next day.
As Vention’s pioneering Advanced Polymers team was the first to manufacture balloons for the medical device industry, Vention brought a deep understanding of material properties, the medical balloon-forming process, and precision extrusion technology to develop the best components for the application.
Throughout the design process, the team used Design for Manufacturability to ensure efficient manufacturing of a high-quality medical balloon. It was an extraordinary challenge to manufacture balloons with such difficult dimensional requirements along with tight specifications at production volumes.