Precision Laser

Micro-Machining

Laser cutting, welding, ablation and marking for medical device components, made to print in our ISO 13485:2016-certified facility.

Precision laser micro-machining uses a tightly focused laser beam to cut, weld, ablate or mark features too small or delicate for conventional tools. The beam never touches the part, so thin walls don’t deform, there’s no tool wear, and features repeat part after part.

NorthStar applies it to medical device components in metals and polymers, from first prototype through production.

Materials we process: 304 stainless steel · 316 stainless steel · stainless steel cable · flat sheet stock · polyimide · PTFE · braid-reinforced polymer tubing

What is precision laser micro-machining?

Hypotube & Thin-Wall Laser Cutting

We laser cut slots, spiral patterns and hole arrays into stainless steel hypotubes, thin-wall tubing and flat sheet. Every cut delivers clean, burr-free edges and consistent inner and outer diameters. Cut patterns let you tune a tube’s flexibility, torque response and kink resistance for catheter shafts, delivery systems and minimally invasive instruments.

Hypetube with micro-hole array

Capabilities & Specifications

  • 304 stainless steel hypotube, rotational cutting

  • Tube: .153" OD × .007" wall

  • Array of 24 holes, .007" diameter each

  • Perimeter holes: .032" diameter

  • Kerf widths: .012" to .015"

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Slotted 316 stainless steel tube

Capabilities & Specifications

  • Cutting and marking on 316 stainless steel

  • Tube =  .127" OD X.016" wall X .538" length

  • Slot = .057" X .252 length and .030" X .090"

Welded and slotted 304 stainless steel tube

Capabilities & Specifications

  • Welding, cutting and marking on 304 stainless steel

  • Tube: .248" OD × .027" wall × 1.5" length

  • Slots: .027" wide × .658" long

Flat sheet stock cutting

Complex 2D profiles cut from flat sheet stock with clean, burr-free edges.
Request a Cutting Quote
Close-up of three metal tubes with open ends, placed on a white surface.

Laser micro-welding joins miniature metal parts with a small, controlled heat-affected zone, so fine cable, wire and thin-wall bands keep their geometry. We combine welding with cutting and marking on the same part, which removes handoffs between suppliers.

Example: cable-to-band weld

  • 304 stainless steel cable welded to stainless steel band

  • Cable = 12 strand X .009" diameter

  • Anchor band = .092" OD X .010" wall

Laser micro-welding

Request a Welding Quote

Polyimide & PTFE laser ablation and stripping

Laser ablation removes polyimide, PTFE and other polymer layers in controlled passes, exposing the braid or metal beneath without mechanical stress. Use it to open slots and windows in braid-reinforced tubing, add functional texture, and apply high-resolution marks across complex device surfaces.

Braid-reinforced polyimide tube with PTFE liner

Capabilities & Specifications

  • Ablation through polyimide and through PTFE

  • Tube: .096" OD × .006" wall

  • Slot: .030" wide × .125" long

From functional texturing to high-resolution marking, ablation improves performance, identification and compliance on flat and cylindrical parts.

Request a Welding Quote

High-definition laser marking

We produce deep, ultra-dark laser marks for logos, serial numbers, part identifiers, and orientation or depth indicators, with crisp definition and exceptional readability.

A collection of metal rods with black rings, arranged diagonally on a white surface, with the text 'Part A' in blue font at the top left.

Depth markers on stainless steel tubing

  • Marking of stainless steel tubing

  • Diameters from .010" to 6.00"

Close-up of a metal part with a ruler attached, labeled Part B, indicating measurements from 5 to 40 centimeters.

  • Linear graduation marking

  • 1 mm to 50cm capability

Linear graduation marking

Request a Marking Quote
A metallic stun gun with a blue handle and a cylindrical body, labeled 'INTEGRA' and 'PCC.'

Complex Sub-assemblies

We manufacture the high-precision components at the core of minimally invasive and implantable devices, then assemble them. Cutting, welding, ablation, marking and assembly under one quality system means fewer suppliers and fewer handoffs.

Discuss Your Sub-Assembly

Commercial applications

Our laser and micro-manufacturing processes also serve industrial, commercial and consumer products that need precision and durability, such as permanently marked threaded fittings.

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What Our Customers Say.

  • Sam L. (FLORIDA)

    “The first surgery has been completed with great success and a positive outcome for the patient…you are directly helping improve the quality of people’s lives!”

  • Angela H. (MINNESOTA)

    “Wow! You did a great job with these parts. Thank you for turning around so quickly.”

  • Michelle R . (CALIFORNIA)

    “You weren’t kidding, your turn around time is great! I wish all lead times were like this.”

  • John S. (WISCONSIN)

    “You continue to establish and maintain one of the finest and well-documented ISO systems…it is the best as far as written documentation, organization, and creativity.”

  • Eric B. (MISSOURI)

    “Your parts and lead time were great. We are finalizing this project in the field, and we will be placing another order in the next few weeks to supplement production.”

  • Marcia L. (ARIZONA)

    “Thank you for fitting us in sooner than you expected. I really appreciate all you’ve done to get this done.”

Laser processing FAQs

  • Medical device makers use laser micromachining to cut hypotubes and catheter components, weld miniature metal parts, ablate polymer layers and permanently mark parts. It suits small features and thin walls that conventional machining would distort.

  • A laser-cut hypotube is a thin-wall metal tube with a cut pattern of slots, spirals or holes that sets how it bends, transmits torque and resists kinking. Catheters, guidewires and delivery systems use them. One of our examples is a .153" OD 304 stainless steel hypotube with a .007" wall and 24 holes of .007" diameter.

  • Yes. We ablate through polyimide and PTFE in controlled passes to expose the braid, for example .030" × .125" slots in a .096" OD braid-reinforced tube with a .006" wall. We confirm each new material stack on samples first.

  • Yes. We run rapid prototypes and quick-turn samples, then scale to high-volume production under the same ISO 13485 quality system.

Have a drawing? Get a quote.

Send your print, material and annual volume. We’ll review it and reply with next steps. Need supplier qualification documents? See our certifications →

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