Braiding technology that saves lives

Sometimes it’s a tiny implant that saves a life: a stent that ensures blood flow. Manufacturing these small lifesavers is a highly precise, technically demanding process. Admedes and B&R, the Machine Automation Division of ABB, reimagined stent production – and developed a braiding machine that sets new standards.

Traditional wire braiding machines for stent manufacturing quickly reach their limits: they are either highly productive but barely adaptable—or flexible, yet slow in production speed. With B&R’s control architecture and servo technology, Admedes overcame these challenges and implemented a new generation of braiding machines. “Our customers in the medical industry increasingly demand customized design solutions and rapid prototypes,” explains Dirk Heining, Managing Director of Admedes, one of the world’s leading manufacturers of Nitinol components. This sparked the vision of a new stent braiding machine: “It should dynamically adapt to different designs, wire counts, and braiding patterns—without compromising on quality or speed.”

Admedes developed a highly complex circular braiding machine with individually driven flyer wheels and an innovative magnetic switch system. This allows braiding patterns and wire counts to be varied flexibly—without any manual adjustments. “The implementation of this novel machine concept confronted us with three major challenges,” explains Marc Bräuner, Teamlead Wire Technologies Development at Admedes:

• Flexible bobbin path: The wire-guiding bobbins must be transferred between paths using magnets without mechanical components – a function previous machines did not offer.
• Synchronization of 96 servo motors: All motors must be precisely synchronized on a single CNC core.
• Compact freedom of movement: The bobbins should move both radially and translationally – while maintaining a compact design.

No automation manufacturer on the market could meet these requirements with standard solutions – until Admedes turned to B&R. “With B&R, we found a partner whose control architecture and engineering expertise enabled us to make this vision a reality,” says Heining. Through close collaboration between Admedes and B&R, a solution was developed that goes far beyond standard technology. “Our strength lies in understanding our customers’ needs and finding ways to implement them together,” explains Jonas Mittwich, Sales Representative at B&R. “In developing this highly complex machine, it was clear: only through close exchange could we turn requirements like flexibility and precision into true innovation.”

The new Admedes braiding machine is a prime example of high-precision automation: by integrating the latest B&R technology, a system was created that controls complex motion sequences impressively fast and accurately. The Automation PC 910 serves as the control center, coordinating 96 flyer wheels powered by 32 ACOPOS P3 servo drives. 384 individually controlled magnetic switches enable dynamic bobbin transfers between different braiding paths – a crucial step for realizing variable patterns and complex designs. The machine processes between three and 192 wire ends at flyer wheel speeds of up to 300 rpm. Radial and translational movements are executed precisely, and decentralized I/O modules keep the design compact and efficient. “Synchronization was extremely demanding. But with B&R servo technology, we achieved the scalability, precision, and flexibility required,” emphasizes Braeuner. “The machine runs up to ten times faster than previous flexible braiding machines.”

With this new braiding machine, Admedes takes stent production to an entirely new level – faster, more flexible, and more precise than ever before. Supported by two renowned universities and funded by the Federal Ministry of Education and Research, these machines can contribute to improved medical care. “Without B&R, this machine wouldn’t exist,” stresses Heining. “Together, we pushed the limits of what’s technically possible and developed a solution that can save lives.”