Vention collaborated closely with the customer to develop a detailed project plan and meet tight timelines. The team worked through many iterations with different tip angles and geometries as well as tubing diameters to achieve the functional requirements. The customer also asked Vention to modify the design of the proximal end, which had been square. Vention’s new design included a lead-in funnel to ease the transition. Vention was able to build and ship prototypes for customer evaluation within 10 days.
The customer then presented Vention with an additional challenge: to make the tube transparent so that the user could visualize the implant through the thick walls of the tube. Polyethylene extrusions generally have a matte surface. The team quickly iterated and developed a proprietary extrusion process to achieve the transparency goal. The team had to develop all-new tooling and conducted many trials to consistently achieve a smooth surface. Vention also built a dedicated manufacturing cell within 6 weeks with all the tooling and equipment needed for one-piece flow and just-in-time manufacturing.
The Vention team brought years of expertise in extrusion materials and processing, as well as in catheter tip forming and processing, tooling design, validation, and project planning and management.