Your balloon component partner from prototype to production
High Technology Balloon Components Delivered Faster
100+ Combined Years of Experience
Compliant, Semi-Compliant & Non-Compliant
In-House Blow Molding
Full Testing & Characterization
Scalable to Full Catheter Development
Custom Material Formulations
Rapid Prototyping & Iteration
Regulatory-Grade Documentation
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We've been building balloons for a long time. Now we're building a department around it.
Balloon development at LightningCath didn't start with a press release. It started with a problem. Device teams needed a partner who understood the nuance of balloon selection, the complexity of material behavior under pressure, and the rigor required to produce a component that performs in a clinical setting.
With over 100 years of combined balloon expertise, we've built this capability from the ground up. We learned the materials, refined the process, developed the testing infrastructure, and helped device companies solve problems at every stage of development.
Now we've formally launched the Balloon Components Department to make that expertise more accessible and to work with more of the device teams who need it.
Partner with LightningCath
Collaborative partners invested in your device's success. Let's discuss how we can accelerate your balloon development.
Every balloon type, In-house
From material selection to characterization. Everything under one roof.
Low Pressure • Anatomically Conforming
Stretches beyond molded diameter. Conforming, low-pressure. Ideal for occlusion applications where the balloon needs to conform to vessel anatomy without exerting excessive radial force.
Moderate Flexibility • Predictable Shape
Slight stretch with a predictable, controlled shape. Used in angioplasty, drug-coated balloons, and neuro applications requiring controlled dilation and moderate flexibility under pressure.
High Pressure • Precise Diameter
No stretch. High-pressure precision. Critical for stent and valve deployment where exact diameter must be maintained at rated pressure. Minimal growth across the pressure range.
Nylon
Versatile balloon tubing for semi-compliant applications. Excellent burst strength with predictable inflation profiles across a range of diameters.
Pebax (PEBA)
Multiple durometer options for tailored compliance characteristics. Ideal for applications requiring controlled expansion and superior flexibility.
TPU
Thermoplastic polyurethane options including Pellethane and Tecoflex for applications requiring balloons with high expansion ratios and unique occlusion capabilities.
Custom Formulations
Custom polymer blends, radiopaque-loaded compounds, and additive formulations engineered to meet unique performance specifications.
PET (Polyester)
High-strength non-compliant balloon tubing for demanding high-pressure applications. Minimal diameter growth at rated pressures.
Multi-Layer Constructions
Co-extruded multi-layer balloon tubing combining different polymer properties for optimized compliance, strength, and trackability in a single design.
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Balloon Tubing Extrusion
Precision extrusion of balloon-grade tubing in Nylon, Pebax, PET, TPU, and custom formulations with tight dimensional control.
- Single and multi-lumen profiles
- Tight OD and wall tolerance control
- Custom formulations and blends
- Consistent lot-to-lot performance
Balloon Forming
Full balloon forming from tubing through finished balloon with precise dimensional control and compliance profiling.
- Compliant and non-compliant designs
- Custom tapers and shoulders
- Multi-diameter balloon profiles
- Low-profile folding and wrapping
Pleat / Fold Assembly
Balloon pleat / fold and catheter assembly to integrate finished balloons onto your catheter shaft for a complete subassembly.
- Balloon-to-shaft bonding
- Radiopaque marker integration
- Stent loading and crimping
- Custom packaging configurations
Testing & Validation
Comprehensive testing to validate balloon performance against your design requirements and regulatory standards.
- Burst pressure testing
- Compliance profiling curves
- Fatigue and cycle testing
- CoC documentation
PARAMETER
RANGE
NOTES
Balloon OD (Inflated)
1.5 mm – 30 mm
Full Range
Wall Thickness
Down to 0.0002"
Application-dependent minimums
Balloon Length
Up to 390 mm
Custom lengths available
Multi-Diameter Profiles
Available
Stepped and tapered designs
Balloons built for interventional specialties
From coronary and neurovascular to structural heart, our balloons are engineered for the most demanding clinical applications.
PTA & Coronary Dilation
Peripheral Vascular
Structural Heart
Neuro Interventional
Stent Delivery
Electrophysiology
Diagnostic Sizing
Occlusion
Valve Deployment
Urology
Sinuplasty
Orthopedics
Need balloons for a specific clinical application? Our team has expertise across all interventional specialties.
Fast to start. Rigorous all the way through.
You don't need a completed spec to talk to us.
01
Tell us what your device needs to do
Share the application, the anatomy, the performance goals and we'll take it from there. This is where years of application experience pays off.
02
We recommend the right balloon
Material, compliance type, dimensions, operating pressure; a clear recommendation with the reasoning so you understand the tradeoffs before committing.
03
We make it and test it, fast
Blow molded in-house, characterized against your requirements, tested with the data package to show it. The process is dialed, so we move quickly.
04
Scale as you need it
From R&D samples to production volumes. And if your device grows beyond the balloon, the broader Switchback platform supports full catheter development.
See What We Can Build Together
Whether you're in early concept or preparing for production, our team can help optimize your balloon design and manufacturing.
Strong partner expertise. A dedicated team. All under one roof.
Most balloon suppliers ask what size you need. We ask what your device needs to accomplish.
Proven Experience
You're not our learning curve. A 100+ years of real balloon development across the full range of interventional applications.
Competitive Lead Times
Established process, tooling, and expertise means competitive lead times from brief to balloon in hand without cutting corners.
Regulatory-Grade Data
Every balloon comes with characterization and testing documentation. the kind that holds up in a regulatory submission.
Full Material Compliance Spectrum
Compliant, semi-compliant, and non-compliant under one roof. no need to split your supply chain across vendors.
Scalability
R&D to production, balloon to full catheter. all within the Switchback platform. No starting over with a new vendor.
Partnership, Not Just Parts
A development partner who shapes the device from the start. not a supplier bolting on a component at the finish line.
See What We Can Build Together
We offer free consultations for new projects. Tell us what you're working on. We'll tell you exactly where to start and how fast we can move.
TALK TO AN EXPERTNot ready to talk yet? Browse our capabilities, follow us on LinkedIn or subscribe to our newsletter for updates.
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