Optimization of the Heat Bonding Process for Pacemaker Leads: Conceptual Design and Finite Element Analysis

Abstract

This project aims to optimize the heat bonding process used in the manufacturing of pacemakers and leads to bradycardia treatment by redesigning the thermal assembly to improve temperature uniformity, process efficiency, and structural alignment. The original system, which used a dual-stage heating process and an INVAR 36 [1] bar with copper inserts, exhibited significant thermal gradients and misalignment due to thermal expansion. To address this, a new design was developed incorporating Celazole [2] thermal insulators. Finite Element Analysis (FEA) [3]F was performed to evaluate thermal behavior. The updated thermal architecture significantly improved temperature consistency across all bonding zones, with improved control and efficiency. Keywords - Celazole, FEA (Finite Element Analysis), INVAR, Thermal Control.