By Sean Fenske, Editor-in-Chief

The medical device industry strives to shrink. That is, not in terms of the size of the market, but rather, in the size of the technologies being used in healthcare procedures. Minimally invasive innovations have been the trend for several decades, and there are no signs of it changing significantly anytime soon. As such, device designers need to be aware of what is required for these products.

Like so much of healthcare, plastic is used for many aspects of these devices. However, arguably more important are those components made of metal. Providing strength, durability, and reliability at the required miniature size, metal parts provide these and additional benefits for minimally invasive device developers.

To help further illustrate these advantages and offer additional insights on the applications for metal within medical devices, Steven Langan, VP & GM – Metals at Freudenberg Medical, participated in the following interview. In this Q&A, he speaks to when and where metal is preferred, how it can complement other materials, and how his company can support its use.

Sean Fenske: While so much of the medical world is plastic, metal still has a place. Where is that place and why? For those applications, why is it still a better option?

Steven Langan: While plastics may often take the headlines, metals can be the workhorse in minimally invasive therapies. Beyond implantable metal devices, metal-based tubing, including hypotubes and laser-cut tubing, continues to play a critical role in catheter applications where strength, flexibility, and precise control are essential. Wherever a device must navigate tortuous or hard-to-reach anatomy—such as in cardiovascular, peripheral vascular, or neurovascular applications—metal solutions provide unmatched performance for access and delivery. Beyond these use cases, metal tubing is vital in applications requiring high levels of steerability, torque response, and high-load bearing, such as structural heart interventions. In these demanding scenarios, metal is not just a viable option—it’s often the superior one.

Fenske: Do manufacturers come to you with a challenge and seek advice, where you can suggest metal when it is the best option, or do they already have metal in mind?

Langan: It can vary. In some applications, like arterial delivery, a metal-based solution is widely recognized as the optimal choice. In others, manufacturers may be evaluating alternatives, such as braid or polymer solutions. In both cases, customers turn to us for expert guidance—where we thrive on early engagement to understand their specific performance needs and recommend the right metal solution. Finding the perfect metal-based design is a blend of art, metallurgy, and engineering—making it essential to work with a partner who has deep, cross-application expertise. With over 20 years of experience, we support more than 70 medical device companies across 24 countries and ship over 10 million metal hypotubes and laser-cut tubes annually. Our expertise is deep and broad. Engaging the right partner from the start helps avoid costly redesigns and ensures the device performs as intended.

Fenske: Are there opportunities to leverage metal with another material to maximize or increase benefits?

Langan: Absolutely—there are many opportunities to combine metal with other materials to enhance overall device performance. These hybrid solutions are especially valuable in applications requiring advanced steerability, precise navigation through tight anatomical spaces, smooth and accurate device deployment, repositioning capabilities, and lower profiles. While steerable catheters are often considered predominantly polymer-based—such as braided or coiled designs—it’s the metal components, like pull-wires or laser-cut tube sections, that provide the critical backbone enabling controlled movement. Hybrid metal-polymer systems allow for fine, multi-directional steering across various reaches and radii—performance that polymers alone often can’t achieve. Most metal designs will also feature some form of hub or deployment handle as well, so overmolding considerations also need to be taken into account, especially for support in device transition zones. Metals are also increasingly used in intravascular imaging systems that integrate optical technologies. And finally, the external coating or surface finish material of the metal component is another key factor, as it is vital to the overall performance and feel of the device in the physician’s hands.

Fenske: What other services does Freudenberg Medical offer that can complement its metal offerings?

Langan: Freudenberg Medical offers a fully vertically integrated suite of design, development, and manufacturing services across our 12 global sites—including braiding, extrusion, molding, coatings, and assembly—which complement our metal solutions and create strong synergies in catheter development. Unlike CDMOs that specialize in just one capability area, we support the entire value chain. This allows us to focus on what the customer actually needs, not just what we have to offer. Rather than forcing a design to fit existing capabilities, we combine the right technologies to deliver the best solution based on clinical performance goals. And as a fully integrated partner, we take end-to-end responsibility—reducing supplier complexity, optimizing costs, and minimizing risk for the customer.

Fenske: I understand Freudenberg Medical has made an acquisition relevant to its offerings in metal. What was the purchase, and what’s the impact for customers and on capabilities?

Langan: We’re excited to have recently acquired Fuji Seiko, a Japanese manufacturer known for its high-quality, small-diameter metal tubing. This move supports our goal to build the most vertically integrated metals supply chain in the industry. Fuji Seiko has spent over 30 years building an unparalleled reputation for quality and is widely recognized as a leading supplier to top OEMs. In fact, its raw tubing set the industry standard, so it is synonymous with the bulk of metal-based catheters used in cath labs today. For our metals customers, the benefits are immediate. Faster lead times begin with raw material procurement, and now having Fuji Seiko in-house gives us greater control and responsiveness. As we integrate and invest in Fuji Seiko, we also plan to expand its tubing size range and metallurgy capabilities while maintaining the same high standards of Japanese engineering and precision that are the hallmark of Fuji Seiko’s industry reputation.

Fenske: What often overlooked aspect should medical device developers keep in mind when working with metal? What opportunities/benefits are missed?

Langan: One often overlooked aspect is how early material selection and processing decisions impact the entire lifecycle of a catheter design—from performance and manufacturability to supply chain resilience. Developers sometimes focus heavily on geometry or tolerances, but underestimate the critical role of raw material quality, consistency, and how the tubing was manufactured—whether through drawing, heat treating, or surface finishing. Engaging with a metals partner early can unlock design improvements in torque, flexibility, and pushability—without changing the device geometry. And working with a vertically integrated supplier adds value through shorter lead times, better consistency, and greater innovation potential.

Fenske: Do you have any additional comments you’d like to share based on any of the topics we discussed or something you’d like to tell medical device manufacturers?

Langan: Freudenberg Medical is part of the Freudenberg Group, a company with over 175 years of materials science expertise. That legacy—rare in today’s medtech market—deeply shapes how we approach the industry, our technical portfolios, and our commitment to customers. In metals, materials science isn’t just important—it’s foundational.

As a privately held company with a long-term orientation, we put the customer at the center of everything we do. It’s a mindset that differs markedly from the short-term, transactional focus that can emerge in periods of rapid consolidation and platform structuring. More and more, our customers are telling us how much they value continuity, reliability, and a partner at scale, like Freudenberg Medical, who invests for the long haul. That’s exactly what we offer: enduring, value-driven relationships built on trust, quality, and sustained innovation.

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