Soldering means melting and molding metals together by using another metallic alloy.  This is done by using a metal that melts at a low melting point. Micro soldering is best explained as joining wires that are thinner than human hair at a diameter of 9 microns.

The rate at which the medical field has advanced in today’s world has led to a rise in the need for miniature medical devices. The demand for manufacturers that can produce miniature medical sensors and micro-coiled wires has risen.  A manufacturer needs to show they can join very fine wires and introduce innovative methods that traditional welders can’t. Micro-wires are used in the production of coils, which are wound and used in the production of miniature medical sensors.

These wires have to meet strict requirements and tolerate a diverse set of challenges. Because of these strict requirements, traditional methods of welding can’t be used. Since these wires are required to be very thin and are used in delicate medical procedures, they need specialized and technical knowledge in their production.

What are the traditional methods of soldering?

There are two methods of traditional soldering, namely:

  • Heating a metal filler to join two metals by using external heat.
  • Using electricity to melt and weld the metals that require joining.

These traditional methods can’t possibly be used in micro soldering because of the physical constraints that they produce, some of the issues they introduce are:

  • Traditional welding methods produce uneven heat, which ends up ruining the wires.
  • The area surrounding the wire and the wire itself oxidize.
  • The wires are not reliable and degrade because of physical strain.

The solution to these challenges is through innovative welding methods, like bonding the wires together using thermo-pressure technology. To achieve this, there is a need to use an innovative manufacturer who can connect very fine wires, whether they share the same diameter/material or are different and the materials used are different.

Using thermos-pressure technology can connect:

  • Used to connect very fine wires to tiny copper thermocouples.
  • Connect tiny coils to a support system using terminals that have been metal plated.

The connection made by using this innovative technology produces reliable wires that are not corrosive and free from strain. This process is also more economical and is easy to mass-produce and can sustain the high standards that are set by medical boards.

What are the applications of micro soldering?

  • It’s used in the production of implants which are used in monitoring and controlling devices such as pacemakers.
  • Used in the production of diagnostic devices like miniature medical sensors.
  • Used in the manufacture of devices that are used in therapeutic treatment.
  • Manufacturers use this method to create devices that are used to deliver targeted medication.

Noting that this is a relatively new field, there are limitless opportunities in miniaturized medical technologies. This field requires the expertise of highly specialized manufacturers who has the capacity to design unique and innovative machinery.  Any manufacturer who is well versed and has experience in the field of micro-soldering can venture into other areas creating miniature medical devices.