Laser Cutting

Laser-cut wire

Laser Cutting

The world’s most advanced – and smallest – minimally invasive devices would be impossible to manufacture without laser micro-cutting. Resonetics offers a wide range of laser cutting services, offering countless shapes and dimensions for the life sciences industry. This micro-cutting includes cutting, sizing, singulation, edge refinement and de-gating of polymer-based components and devices.

Laser Cutting Capabilities

We use direct-write diode-pumped solid-state (DPSS) lasers operating in the deep UV (ultra-violet) spectrum. These high repetition rate lasers are able to direct write a small spot (typically as small as 10 to 15 microns in diameter). The laser beam follows the path of the cut out, much like a die cut except there is no tool wear. By operating at laser wavelengths of 266nm or 355nm, the polymer material is ablated or vaporized, with little melting or debris resulting from the cut. As a result, your component is precisely machined, meeting the most stringent quality requirements.

We perform large area skiving or 3-D device cutting by using mask projection UV excimer systems (also called mask projection imaging). The laser illuminates a mask defining the ablation pattern, which is then imaged onto the work piece. Operating wavelengths of 248nm or 193nm afford high quality cuts with little melting or debris.

Bioresorbable stent showing laser cutting

Laser Cutting

Our laser cutting capabilities include experience in handling:

  • Material thickness as high as 1-mm.
  • Kerf width as low as 15-microns.
  • Choice of singulation or leave-on substrate with holding tabs.
  • Bioresorbable materials, including their handling, storage and packaging.

Applications for Laser Micro-Cutting Medical Devices

Laser cutting is used in the manufacture of a wide range of medical device and diagnostic components. Some common clinical specialties include cardiac rhythm management, electrophysiology, diabetes management, minimally invasive surgery, interventional therapeutics and molecular diagnostics.

Catheter with laser-cut slot

Laser Cutting

Resonetics, for example, offers:

  • Flat sheet micro-cutting for singulation of sensors.
  • Tubular micro-cutting for catheter skiving.
  • 3-D device micro-cutting for filters and embolic protection devices.


Our experience includes precision laser cutting of most commonly-used
materials in the life sciences, including:


  • Polyethylene
  • Nylon
  • PMMA
  • PEEK
  • Polycarbonate
  • ABS
  • PEN
  • Polyimide
  • Polyurethane
  • Silicone
  • PET
  • Polystyrene
  • Thermoplastic elastomers
  • Fluoropolymers
  • Polypropylene
  • Parylene
  • Polysulfone
  • Bioresorbables
  • Pellathane

Bioresorbable Polymers

  • Poly-L-lactic Acid (PLLA)
  • Polycaprolactone (PLC)
  • Polyglycolic Acid (PGA)


  • Alumina
  • Zirconia
  • PZT
  • Silicon carbide
  • Aluminum nitride
  • Tungsten carbide


  • Tantalum
  • Tungsten
  • Tungsten carbide
  • Nitinol
  • Cobalt
  • Platinum
  • Molybdenum
  • Titanium
  • Stainless steel
  • Various alloys


  • Borosilicate
  • Sapphire
  • Diamond
  • Ruby
  • Pyrex
  • BK7
  • Soda lime glass

PDF Download our laser cutting sales sheet