Conair and Partners Showcase Multi-lumen Catheter Production at MD&M WestConair and Partners Showcase Multi-lumen Catheter Production at MD&M West
Conair is working with Davis Standard and Zumbach Electronics to demonstrate extrusion of small, tapered, multi-lumen surgical catheters made from TPE at the event.
January 22, 2025

Conair Group, in collaboration with technology partners Davis Standard and Zumbach Electronics, will spotlight a complex and highly precise medical manufacturing process at MD&M West 2025: The extrusion of small, tapered, multi-lumen surgical catheters made from thermoplastic elastomer (TPE).
MD&M West is set for Feb. 4 to 6, 2025, at the Anaheim Convention Center in Anaheim, CA. The event is North America’s largest annual manufacturing trade show, covering the medtech, plastics, automation, and design and manufacturing sectors.
This live demonstration will take place at booth 4320, and will spotlight the capabilities required to produce the precision tubing used in minimally invasive surgeries and medical procedures.
Multi-lumen catheter extrusion
The catheter segments being produced during the show are considered to be an engineering challenge. Each segment requires continuous dimensional control, both externally and internally, to meet the exacting standards of medical device manufacturing. Over a length of 24 in., the outer diameter of the catheter tapers from 0.140 in. at the body to just 0.110 in. at the tip.
Inside, the catheter contains three lumens: two crescent-shaped outer lumens and a central lumen with an internal diameter of only 0.005 in. According to the company, these lumens must maintain precise dimensions as they taper along with the outer tube, all while ensuring the tube’s outer wall remains consistent.
At MD&M West, the live demonstration will feature a multi-step extrusion process. Medical-grade TPE and additive masterbatch will be fed into a Davis-Standard 1-in. High Performance (HPE) medical extruder via Conair AL-2 and TLM loaders, blended in a Conair TrueBlend TB45 blender. Temperature control and process cooling will be provided by a Conair EP1A portable chiller and a Thermolator TW-T temperature control unit.
The TPE extrudate is driven through a Guill cross-head die, where air inputs from three Zumbach SPV-1 digital airboxes are injected to inflate and pressurize the hot tube, creating the internal lumens. The extrudate then passes through a water-filled sizing/calibration tool, which uses a vacuum-controlled layer of water to gently shape the tube’s outer diameter without causing friction or damage.
From that point, the extrusion then continues into a Conair MedVac 238 vacuum cooling tank, where precise pressure regulation ensures laminar flow over the tube for optimal cooling. Zumbach UMAC ultrasonic devices measure the tube’s wall thickness, while the Zumbach ODAC laser measures its outer diameter, feeding real-time data into the line control system.
Creating a bump
Conair noted its Medline MLD1-12S puller/cutter unit regulates the variations in line speed and air pressure that create the catheter’s tapered “bump.” The company’s software manages these adjustments, enabling the creation of multi-lumen designs with up to 16 lumens. The puller/cutter system’s air-assisted cutter bushings minimize friction, ensuring consistent, clean cuts for each catheter segment.
The company noted that after cutting, finished catheters are conveyed via its Medline MTAC 406 conveyor. While the extrusion process results in small scrap segments at transition points, these are collected, granulated, and reintroduced into the process at a 10 to 20% ratio, ensuring a zero-waste production cycle.
For more information about Conair Group’s products and services, visit www.conairgroup.com.
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