Laser cut tubing, also referred to as tube laser cutting, is at the heart of innovation in today’s MedTech and life sciences industries, enabling the kind of precision, flexibility, and performance required to bring next-gen devices to life.
Finding the right laser cutting partner can play a critical role in turning complex designs into real-world products. Below, we’ll explore Resonetics’ laser cut tubing services—what they are, where they’re made, and why they’re trusted by some of the most advanced teams in the medical field.
Laser Cut Tubing Services by Location
Resonetics’ laser cut tubing capabilities are distributed across a strategic network of manufacturing sites, with each location complementing the production of a wide range of specialized products.
Davis, California
The Davis facility is home to Resonetics’ laser cut tubing technology, engineered for high-speed hypotube cutting, fiber laser with wet cutting, and specialized laser cut tubing designs for stainless steel.
Following a significant expansion in 2020, Davis now also offers advanced laser welding capabilities, featuring Lightspeed Lab for rapid prototyping and product development.
Processing Scale:
- Outside Diameter (OD): 0.030” to 0.500”
- Wall Thickness (WT): 0.0015” to 0.020”
Kettering, Ohio
Kettering specializes in laser micromachining and welding, delivering high-precision solutions for a number of complex medical components. Specifically for laser cutting, this includes small inside diameter (ID) thin wall tube cutting, femtosecond and fiber tube cutting, and small part post-process cleaning for all drawn metals and rigid polymers.
Its focus on fine-feature laser processing makes it a key site for custom applications, particularly those involving tight tolerances or delicate materials.
Processing Scale:
- ID/OD: Down to 0.002” ID / 0.004” OD
- Thin walls: 0.0005” or thinner
- Tubing OD of 0.035” or smaller
Blaine, Minnesota
The Blaine facility provides advanced laser processing for medical device components and laser cut tubing services.
As a key part of Resonetics’ broader manufacturing network, the Blaine facility plays an active role in delivering the precision and consistency required for high-performance MedTech applications.
San Diego, California
San Diego serves as Resonetics’ primary hub for advanced nitinol processing—including femtosecond laser cutting, shape setting, electropolishing, and welding. With capabilities designed to support ultra-fine, complex features, the site is optimized for demanding applications in areas like neurovascular and structural heart devices.
With the addition of our San Diego Lightspeed Lab in 2022, the site provides development teams with rapid access to micromachining tools and iterative prototyping for nitinol.
Related: Nitinol: The Transformative Material Reshaping the Medical Device Industry
Processing Scale:
- OD: 0.010” (0.254mm) to 0.63” (16mm)
- WT: Up to 0.030” (0.750mm)
Or Akiva, Israel
Resonetics’ facility in Or Akiva expands the company’s nitinol processing capabilities, offering laser cutting, braiding, shape setting, and finishing for advanced nitinol needs.
The Or Akiva facility’s laser cutting specialties include medium to large tubes, femtosecond and fiber cutting with water, finished devices, and surface testing for nitinol and cobalt chrome materials.
Processing Scale:
- OD: Up to ~1” (30mm)
- Tube WT: Up to 0.059” (1.5mm)
- Sheet WT: Up to 0.098” (2.5mm)
Laser Cut Services Overview
Laser cutting plays a critical role in the production of modern medical devices—particularly those requiring small, complex geometries and ultra-precise execution.
Using a highly focused beam of light, laser systems can cut or ablate material with minimal mechanical force and exceptional accuracy. Resonetics offers a range of laser cut tubing services that are closely tailored to the needs of the MedTech industry.
These services support applications that demand fine-feature resolution, minimal heat-affected zones, and clean, burr-free edges. Depending on the material and requirements, Resonetics utilizes multiple laser types—including femtosecond, picosecond, fiber, and Nd:YAG systems, to ensure optimal results for each project.
This means faster prototyping, fewer secondary operations, and more reliable outcomes at scale. Whether you’re working with stainless steel, nitinol, or polymers, Resonetics’ laser processing expertise enables highly repeatable manufacturing for the most challenging part designs.
Related: The Ultimate Guide to Micro Manufacturing in MedTech and Life Sciences
Types of Materials for Laser Cut Tubing
Resonetics works with a variety of high-performance materials chosen for their strength, biocompatibility, and responsiveness to precision laser cutting.
The most commonly used material is 304 stainless steel, valued for its durability and corrosion resistance in medical environments. Other stainless alloys—such as 304L, 316, 316L, 17-4PH, and 17-7PH—offer variations in strength, machinability, and carbon content to match specific device requirements.
For applications that demand enhanced flexibility or unique mechanical properties, cobalt chrome and nitinol alloys are also available. These materials are especially useful when stainless steel alone doesn’t meet the design or performance criteria (e.g., in shape-memory components or high-strain environments).
Laser systems are selected based on each material’s characteristics—factors like hardness, reflectivity, and desired edge quality. Resonetics’ ability to cut across this full spectrum of tubing materials allows us to support a wide range of geometries and wall thicknesses, without sacrificing precision or processing efficiency.
Cut Types for Laser Cut Tubing
Different cut patterns offer different mechanical benefits, and Resonetics works closely with product development teams to match the right pattern to each application.
Below are some of the most common types and their applications:
- Interrupted Spiral Cut: Alternates between flexible and rigid zones while keeping the tube structure continuous. Offers controlled bending and solid torque response—ideal for catheter shafts that need to flex and steer without sacrificing strength.
- Spiral Cut: Provides continuous flexibility along the full length of the tube. Commonly used in devices navigating tight, complex anatomy, e.g., neurovascular or peripheral vascular systems.
- Puzzle Cut: Uses interlocking patterns to let two sections of tubing join together—great for combining materials like nitinol and stainless steel while maintaining lumen integrity and joint flexibility.
- Dogbone Pattern: A repeating series of narrow and wide segments that offer targeted flex points. Often used where bending needs to be controlled without losing trackability.
- Brickwork Pattern: Staggered openings in a grid-like structure that balance flexibility with structural support. Suitable for designs where multi-directional movement is needed.
- Ball and Socket Pattern: Curved interlocking shapes that offer high flexibility and articulation, especially useful in components requiring multi-axis motion.
Sizes and Tolerances for Laser Cut Tubing
Resonetics supports a wide range of tubing sizes and shapes:
- Outer diameter (OD) capabilities range from as small as .004” up to ~1”
- Wall thicknesses can be as thin as .0005”, depending on the material and application
- Shapes include round, square, and rectangular tubing profiles
- Cut types and designs vary based on performance needs (see previous section)
- Tolerances are typically held to ±0.0005”, with tighter specs available in certain cases
These parameters make it possible to laser cut components with extremely fine features while still maintaining structural integrity.
Why Choose Resonetics for Your Laser Cut Tubing Services?
Resonetics brings together proprietary laser systems, deep MedTech expertise, and rapid prototyping capabilities to deliver laser cut tubing solutions that meet the demands of innovative medical device design.
Paired with the hands-on support of the Lightspeed Lab, customers get faster iterations, smarter design feedback, and a smoother path from prototype to production.
Ready to prototype or scale your next device?