en.Wedoany.com Reported - UK-based Laser Wire Solutions has developed a high-precision desktop laser wire stripping system, the Odyssey-8, utilizing MKS Spectra-Physics' Explorer One ultra-compact ultraviolet laser. It can process ultra-fine wires with diameters less than 0.2 mm without damaging the conductor, addressing the issue of inconsistent mechanical stripping quality in medical device production.
Laser Wire Solutions, headquartered in Cardiff, UK, specializes in providing laser processing equipment and engineering solutions for demanding manufacturing applications in the medical, electronics, aerospace, and automotive sectors. Over 90% of its machines are exported, making it a recognized leader in laser wire stripping. New product development often originates from dedicated OEM projects, where the team first collaborates with clients to develop laser processes, then engineers production-ready systems for specific applications.
The client for this project was a medical technology company. The client was unable to commence production due to substandard quality in the mechanical wire stripping process for a new product. Factory space constraints meant that only micro-abrasive blasting could be used for mechanical stripping of catheter electrode wires, but results varied significantly between operators, leading to process validation failure. The client sought a laser-based desktop solution of identical dimensions. William Tindle, Applications Manager at Laser Wire Solutions, noted that many life-saving devices, such as cardiac ablation catheters, still rely on manual operations, resulting in high scrap rates and inconsistent stripping quality. The project's goal was to deliver a robust, repeatable process.
For laser selection, Laser Wire Solutions chose the Spectra-Physics Explorer One HE 355-100 ultraviolet laser. This laser features an "It's in the Box" design, integrating all electronic components into a compact volume of 165mm x 95mm x 76.1mm. The 355nm ultraviolet wavelength enables clean ablation of polyimide and polyurethane insulation layers, while short pulses and high peak intensity minimize the heat-affected zone. During on-site testing, the R&D team achieved spot sizes of 15μm to 20μm, with high beam quality and stability, requiring minimal adjustments after setup for process control.
Ultimately, using this laser as the core, Laser Wire Solutions successfully developed one of the smallest desktop laser wire stripping machines on the market (dimensions 478mm x 168mm x 278mm) within six months. The system is suitable for stripping single, dual, and triple wires, perfectly fitting the limited space of cleanrooms. The client was able to fully validate the production process and launch the new medical device. With significantly reduced scrap rates, improved solder joint quality, and a closed, easy-to-operate process, production also became safer.
Following the success of this client project, Laser Wire Solutions decided to commercialize the solution, naming it the Odyssey-8. This platform has evolved from a client project into one of the most widely adopted desktop stripping platforms in the medical market, with applications expanding from medical device manufacturing to electronics assembly and the aerospace industry—fields where quality is paramount. William Tindle stated that the company relies on this technology daily for critical applications in catheters, vehicles, and aircraft, and depends on partners like MKS, who provide high-end, reliable products, to advance their solutions.
