FilmCast Select™ Case Study: Accelerating Innovation in Filmcast Polymer Technology

In today’s medical device landscape, speed and precision are critical. OEMs are under increasing pressure to accelerate development timelines while maintaining uncompromising standards for quality and performance. This challenge becomes even more complex when material selection plays a critical role in device success.

To address this need, Confluent Medical Technologies developed the FilmCast Select program, a solution designed to simplify material selection and reduce lead times without sacrificing customization or performance.

Understanding FilmCast Technology

The Filmcast coating process begins on the wire's inner diameter and builds outward to achieve the outer diameter. This layered approach is similar to the growth rings of a tree, creating seamless tubing with highly controlled dimensions and properties.

This technology has a long and unexpected history. In 1961, DuPont introduced polyimide Kapton film for electrical insulation applications, particularly in magnet wire used in motors and transformers. In the 1980s, seamless polyimide tubing entered the medical device market when coating adhesion failures in magnet wire revealed a new opportunity. Since then, Filmcast tubing manufacturing has become deeply rooted in the northwest Georgia and southeast Tennessee region, where much of the industry expertise still resides today.

What is FilmCast Select

FilmCast Select™ is a materials customization program that enables OEM customers to intentionally select key performance attributes of FilmCast PTFE and polyimide tubing.

Rather than forcing tradeoffs between speed and customization, the program provides a structured way to align material properties with device requirements from the earliest stages of development.

Case Study #1: The REACH Compliant Challenge

Two customers required REACH compliant polyimide tubing, but each application demanded different performance characteristics.

REACH regulations impose strict limitations on restricted substances in products sold in the European Union. Confluent developed a compliant polyimide formulation that maintains the look and performance of traditional materials while meeting these regulatory requirements.

• For the first customer, optical clarity and ease of post assembly cleanup were critical. Confluent recommended a glossy formulation that provided a smooth surface and reduced bondability, making it easier to remove excess adhesive during assembly while maintaining visual clarity.
• For the second customer, handling and assembly efficiency were the primary concerns. A matte formulation offered improved grip and ease of processing, while also enabling stronger bonding when needed.
• The first option involved Ultra Polyimide, a proprietary material that delivers approximately twice the strength of standard polyimide while maintaining REACH compliance. This provided a direct increase in structural integrity without requiring changes to wall thickness.
• The second option focused on adjusting the braid reinforcement pattern. Drawing on extensive experience in composite tubing and supported by virtual performance modeling, the team demonstrated how braid optimization could improve strength while balancing flexibility.
• FlexaCast PTFE is designed for flexibility, offering more than twice the elongation of traditional ram extruded PTFE. This makes it well suited for applications requiring enhanced navigation through complex anatomies.
• DuraCast PTFE focuses on durability, delivering higher abrasion resistance for applications where wear resistance is critical.
• UltraCast PTFE provides increased tensile strength, resulting in greater rigidity and structural support.

In both cases, FilmCast Select ™ allowed each customer to achieve REACH compliance without compromising on the specific performance attributes required for their device.

Case Study #2: Solving Structural Challenges Without Compromise

A customer developing a braided composite shaft encountered buckling under high compressive loads during downstream assembly. The deformation risked device failure and required a solution that would not negatively impact other performance characteristics.

Confluent evaluated two potential paths:

Both solutions resolved the buckling issue. The customer ultimately selected the braid modification approach due to existing biocompatibility validation, highlighting the importance of flexibility not just in materials, but in problem solving.

Case Study #3: Expanding PTFE Performance Possibilities

PTFE has long been valued in medical devices for its low friction and chemical inertness. However, as minimally invasive devices evolve, customers are increasingly seeking more specialized performance profiles.

FilmCast Select ™ addresses this need with three differentiated PTFE options:

In addition, Confluent has the capability to process customer provided PTFE formulations, further expanding design possibilities.

A Smarter Approach to Material Selection

FilmCast Select ™ simplifies the path from concept to commercialization through a structured, collaborative process.

Customers begin by selecting the performance characteristics required for their application. From there, they choose the appropriate material platform, whether polyimide or PTFE. Finally, Confluent partners with the customer to optimize the design using deep materials science expertise, virtual performance modeling, and cost analysis.

With more than 300 years of combined experience, Confluent helps OEMs navigate complex tradeoffs and make informed decisions earlier in the development cycle.

Conclusion

FilmCast Select ™ represents a shift in how materials are approached in medical device development. It empowers engineers to make intentional choices about performance, reduces development risk, and accelerates progress toward commercialization.

By combining advanced materials, proven processes, and collaborative expertise, Confluent Medical Technologies enables customers to move forward with clarity and confidence.