Catheter Component Processing

SYNEO provides catheter component and guidewire component manufacturing services to a wide range of OEMs and other contract manufacturers. SYNEO services support varying volumes along the device life cycle, from R&D, low volume device manufacturing situations to high-volume, outsourced component and assembly situations.

Component services are available a-la cart or in a multi-operation, turn-key fashion! Talk to a SYNEO contract manufacturing specialist today!

Cut to Length Services

Square and burr-free cut ends and precision lengths are critical for minimizing tolerance stack ups or reducing the risk of butt weld failure. For medical device manufacturers, SYNEO’s custom designed machines create a competitive advantage for our catheter assembly customers.

SYNEO maintains a multi-machine cell of Accu-Cut machines to handle a wide range of tubing and catheter shaft applications. Accu-Cut 202L, 700L, CTXL tube cutting machines and quick-turn tooling resources are available to cut a wide range of braided and non-braided shafts and materials.

Hole Punching, Drilling and Cutting Services

Precise, burr free holes in catheter bodies are critical to catheter device performance and patient well-being. Manual and automated Accu-Drill machines are available to process a wide range of catheter hole drilling and punching applications.


SYNEO’s dedicated applications personnel, equipment and tooling offering provide robust solutions for round, oval, odd-form and off-center skive hole punching applications. Leveraging SYNEO’s hole drilling applications experience and cutting tools featuring Hollow Core Sharpening Technology, single or multi-lumen catheter shafts with complex hole configurations or design patterns are achievable, featuring hole sizes as small as .005″.

Guidewire and Mandrel Tip Grinding and Tip Forming Services

Manual wire deburring and tip grinding is an inconsistent, time-consuming, and costly process. SYNEO maintains an Accu-Tip Automated Tip Grinder (ATG) to serve R&D and low-volume tipping needs of our customers. Small diameter, nitinol or stainless steel guidewires, stylets, or mandrels with radiused or chamfered ends are examples of the tipped component services SYNEO provides.

Catheter Tip Forming & Bonding Services

Flash and burr free catheter tips are essential to an atraumatic device introduction and delivery. SYNEO maintains an Accu-Tip Radio Frequency Tipping (RFT) machine and on-staff plastics engineering resources to serve catheter tip forming needs of our customers. SYNEO’s Accu-Tip forming and bonding equipment can quickly and repeatably provide smooth, accurate transitions for all your catheter devices.


We offer precision tipping and bonding of polyurethanes, nylons and other thermoplastic materials that are required in the fabrication of catheters and other minimally invasive medical devices. SYNEO’s quick-turn, in-house machine shops can provide any tip forming tooling necessary for any specialty tip shape needed.

Identification & Surface Attribute Services

Surface modification through laser marking or sandblasting can be an excellent alternative to traditional depth mark printing on catheters or guidewires. These same surface modification processes can also be leveraged for increase adhesion with glued or insert molded components.


Through internal equipment and external partnerships, SYNEO offers laser marking (laser etching) services, printing services and micro-blasting services for surface removal, serialization, and marker band applications.

Need tubing selection or extrusion support?

SYNEO maintains partnerships with extrusion houses that specialize in medical grade extrusions including silicone, PTFE, and Pebax®. Let a SYNEO contract manufacturing representative connect you with our go-to extrusion partners to get you on the path to success!