Providing Consistency to Coiling Process

HAHN Automation Group Helps Catheter Manufacturer Automate Previously Manual Coiling Process

Increases in product demand often drive the need for manufacturers to transition from a manual process to an automated one. In this example, you can learn about how we helped a medical device manufacturer incorporate automation into their once tedious process. We will call this customer "Oli.” Oli, a vascular catheter manufacturer, was struggling to produce consistent results in a highly complex, manual sub-assembly of their device.

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  • Transition from manual to automated process
  • Produce repeatable, accurate results
  • Reduce cycle time and footprint of assembly



Oli’s previous coiling process called for operators to manually coil a delicate, 0.002”-0.003" thick and 0.020" wide, wire around the exterior of a mandrel at a specified pitch. Doing so required multiple operators to feed, wind, clamp, coil, and cut the material before transferring the device to a welding station—all of which was done by hand leading to long cycle times, inaccuracies, and inconsistency between operators. 


Developing a Solution 

Our engineering teams worked closely with the customer to assess their process, environment, and operators. This allowed us to determine which parts of the process would lend themselves to automation as well as where the customer would see the greatest ROI. Ultimately we designed and built a fully-automated system that would allow operators to load multiple mandrels at once, secure the device, wrap the mandrel with coils of precise spacing, and secure the final product with welding—all inside of the same machine.

Process Overview

  1. The system allows operators to load up to 13 mandrels into the machine at once where they are then indexed and set into position. 
  2. The wire is then coiled along the length of the mandrel and secured at each end. 
  3. Next the system welds the wire into place and inspects the device using integrated vision systems.
  4. After inspection, the final product is released onto a return conveyor where rejects are automatically separated into a reject chute, and approved devices are cycled out every 80 seconds.


Cycle time: 80 seconds for 13 parts


After implementation, our customer experienced better consistency in the coiling of their device that led to greater confidence in the accuracy and effectiveness of their product. This new process also significantly reduced the cycle time and footprint of the process as a whole.