Optimization and Partnership for Reliable Endoscopic Needles
Product Type
Client
Challenge | A Needle That Stops Bleeding Inside the Body
In gastrointestinal procedures, surgeons sometimes need to stop dangerous internal bleeding without opening the patient’s abdomen. Using an endoscope, they insert a long, flexible needle into the digestive tract, flush the area to locate the bleeding ulcer, and then deliver a coagulant to slow or stop the bleed.
These needles—often six feet long and thinner than mechanical pencil lead—must be flawlessly reliable. A failed weld, a hub detaching, or even a bent assembly can have life-or-death consequences. That’s why one of the world’s largest, most recognized medical device manufacturers turned to Hart Enterprises.
Hart’s Solution
Step One: Solving a Welding Problem Others Couldn’t
The Fortune 500 company first approached Hart because their previous supplier’s welds weren’t holding up. Hart’s team produced laser-welded samples for testing that outperformed the competitor’s version. The client quickly shifted manufacturing of the stainless steel components to Hart, trusting Hart with the laser welding, grinding, and assembly of these ultra-fine needles.
Step Two: Fixing the Hub Issue and Proving Reliability
Not long after, the client hit another roadblock: plastic hubs were detaching from the metal assemblies. Hart proposed a new assembly process, prototyped it, and delivered consistent results. Once again, Hart not only solved the immediate problem but also created a more reliable manufacturing method that prevented costly failures downstream.
By this stage, Hart had moved from being a stopgap supplier to a trusted problem-solver—one that consistently delivered when quality mattered most.
Step Three: Streamlining Their Production Process
As volumes scaled, new challenges emerged. The client’s assembly team was damaging parts on their line, slowing production and wasting expensive components. Hart sent its own quality expert onsite to observe. He discovered bottlenecks and inefficiencies: operators manually assembling 11-part subassemblies while million-dollar machines sat idle waiting.
Hart recommended a better path—taking over additional sub-assemblies and packaging in-house. By sending ready-to-use components in custom thermoform trays, Hart freed up the client’s machine capacity and eliminated costly scrap. The client’s throughput increased sevenfold without adding more equipment.
Step Four: Innovating with New Materials
Finally, Hart worked with the client to replace a time-consuming lubrication step with a permanent coating—similar to the non-stick layer on a frying pan. This eliminated drying time, simplified their workflow, and ensured consistent performance right out of the box.
The Outcome: A Scalable Partnership That Grew Over Time
What started as a single problem with weld reliability turned into a full-scale partnership. Hart became not just a manufacturer but a solutions provider—taking on welding, hub assembly, sub-assemblies, packaging, and material innovations.
For the client, that meant fewer failures, more consistent quality, and a massive boost in efficiency. For Hart, it proved that even the biggest names in medical devices value a partner who can solve problems, scale production, and think beyond the blueprint.
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