Insert molding forms the hub, strain relief or connector directly onto the catheter shaft, so the joint is moulded rather than glued. This removes an adhesive interface — usually the weakest point of an assembly — and gives a cleaner transition between the rigid hub and the flexible shaft.
What it solves
- Pull-off strength at the hub, without relying on adhesive
- A moulded strain relief that spreads bending load instead of concentrating it at the hub edge
- Fewer parts and fewer assembly steps downstream
Process notes
- Shaft is positioned in the tool so lumen alignment is held through the shot
- Material pairing chosen so the moulded part bonds to the shaft rather than merely gripping it
- Lumens protected during moulding to keep the inner diameter clear
Typically combined with
Multi-lumen extrusion or reinforced composite shafts where the hub has to carry torque as well as tension.