Microwave Tissue Ablation System - Solero

The Solero Microwave Tissue Ablation (MTA) System and Accessories are indicated for the ablation of soft tissue during open procedures. The Solero MTA System is unique because it is specially designed to complete up to a 5 cm ablation in 6 minutes at max power output using a single applicator. The Solero MTA System is able to accomplish this through the innovative solid-state generator and specially designed applicator. 

The Angiodynamics Solero is a microwave powered ablation catheter. The business end consists mainly of a heated ceramic tip, saline-cooled steel shaft, and a small plastic handle to guide it. HaA’s goal was to see how the current production processes could be improved and if the next-gen catheter could be improved. 

HaA’s role was to assist AngioDynamics in redesigning their Solero handpiece to make it easier to manufacture and to avoid overheating errors and various tip-related issues. 

The current assembly process is quite involved and “finicky”. There are numerous steps including gluing, inserting, compressing, coating, welding and soldering. We began our analysis by looking at the catheter starting at the tip and moving down to the handle.​ 

HaA conducted both research and materials /performance testing to reveal necessary improvements to be made to Solero’s design. HaA also consulted with various manufacturers to gain a deeper understanding of materials and manufacturing constraints related to the old Solero platform and explored options that could improve the new design.  

HaA made design recommendations for the internals of the system and ultimately redesigned the housing into a snap-fit assembly, rather than ultrasonic welding.