Beyond the Sensor: Integrating Pressure Sensing into Catheters at Scale
Sep 29,2026
A tiny pressure sensor is only the beginning. The greater challenge is integrating it into a catheter that can deliver reliable measurements, device after device.
Pressure measurement provides valuable clinical information in applications ranging from intrarenal pressure monitoring and urodynamics to cardiovascular devices. Yet selecting a MEMS sensor small enough to fit is just one part of the development process. Between a bare sensor die and a production-ready catheter lie several demanding engineering challenges.
From sensor die to catheter assembly
Micro-interconnections. Wires only tens of micrometers in diameter must be connected within a confined space. These connections need to remain consistent and robust throughout assembly and use.
Protective packaging. The sensor requires insulation and protection, but its packaging must still transmit pressure effectively. Packaging stress can also affect measurement performance and must be carefully managed.
Sealing. In fluid environments, the assembly needs a reliable seal while maintaining the catheter’s required diameter, flexibility, and response time.
Calibration. Variations in the sensor, wiring, electronics, and assembly can affect the final output. Individual calibration and temperature compensation help ensure consistent measurements.
Making the process repeatable
A few working prototypes are an important milestone. Scaling to thousands of assemblies introduces a different challenge: achieving consistent results across production batches.
That calls for repeatable manufacturing processes, efficient batch calibration, and traceable performance testing. Each step needs to support both the device design and its production requirements.
At Diagsensor Medical, our capabilities span MEMS die interconnection, fine-wire processing, encapsulation, sealing, signal conditioning, calibration, and catheter integration. Our in-house developed Cylinder pressure sensor assembly brings these capabilities together to support pressure sensing in space-constrained medical devices.
The goal goes beyond fitting a sensor into a catheter. It is to deliver reliable pressure measurements at production scale.
Exploring pressure sensing for a catheter or endoscopic device? Contact Diagsensor Medical to discuss your integration requirements.
Sep 29,2026
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