Ablation therapy treats cancer by applying extreme heat or cold directly to a tumour, destroying malignant cells with unprecedented accuracy. Tiny probes or needles are guided into the tumour under imaging, and energy is delivered to create a highly controlled zone to destroy tissue. Because the approach is highly targeted, it can eradicate tumours in situ while sparing most surrounding healthy tissue, offering a local intervention with far fewer side effects.
One of the greatest advantages of ablation therapy is that it is minimally invasive with many procedures being performed under sedation or local anaesthesia, avoiding the risks and recovery time of open surgery. Ablation also sidesteps some of the side effects associated with chemotherapy, such as hair loss, systemic fatigue and prolonged immunosuppression.
For patients with tumours in organs such as the liver, kidneys, lungs or bones who might not be candidates for surgery, this targeted option can be life-saving. As a result, Market Report Analytics now predicts that the thermocouples market is projected to grow at a CAGR of 7% in the coming years, reaching a value of $850m by 2033.
What is the technology behind ablative therapy?
A variety of ablative techniques are now common in modern treatment, each suited to different clinical scenarios. Radiofrequency ablation (RFA) uses alternating electrical current to heat tissue, while microwave ablation uses electromagnetic waves to agitate water molecules and generate heat. Cryoablation, on the other hand, freezes tissue, forming an iceball that engulfs the tumour. New methods, such as focused ultrasound and laser interstitial thermal therapy, also concentrate energy on the target area. Typically, cancer types such as small liver or kidney tumours are destroyed with heat probes, while lung nodules are ablated with cryo or microwave techniques, and bone metastases can be relieved with RFA.
Central to the success of these treatments is the ability to control temperature with extreme precision. Every ablation device includes real-time feedback to avoid overheating or under-treating, which relies on accurate data from a thermocouple consisting of two extremely fine metal wires joined at a junction that generates a voltage proportional to temperature. As the target zone reaches the programmed threshold (for example, 60°C/140°F in RFA or –40°C/-40°F in cryoablation), the system automatically reduces or cuts power to prevent collateral damage. Without this immediate thermal feedback, there would be a higher risk of charring tissue, creating steam pops, or freezing healthy tissue.
To fulfil this critical function, thermocouple wires must meet exacting standards. Firstly, they have to be microscopically thin so the instruments don’t become bulky, with some medical-grade thermocouple wires measuring less than 0.03mm (0.001in) in diameter, thinner than a human hair. At the same time, they must also be exceptionally robust: the insulation coating (often polyimide or similar polymers) has to withstand repeated sterilisation cycles without degrading. The choice of metal alloys is also essential, since different alloys (types K, T, E, N and precious-metal combinations such as platinum–iridium) offer different temperature ranges and sensitivities.
A manufacture of high-grade medical device material
Few OEMs will have the in-house expertise and capabilities to source the right wire and design and develop a perfectly calibrated thermocouple. What sets Alleima apart is its vertically integrated approach, from alloy production to wire drawing and insulation coating controlling every step from melt to market. Finished, easy to integrate thermocouples guarantee the precision and reliability required in medical use. Alleima’s thermocouple offerings cover a wide temperature range, using standard alloys (Type K, T, E, N) and specialised platinum–iridium alloys to handle extreme heat or cryogenic cold. Theyoffer ultra-fine thermocouple wires down to AWG50 (0.0205 mm) and custom configurated alloys tailored to specific medical applications. With a library of more than 200 alloys and decades of collaborative work with medical device OEMs, Alleima delivers performance, reliability, and innovation in equal measure.
Alleima specializes in insulation coating using advanced polymers like ultra-thin poly-nylon , which meet autoclave sterilization and biocompatibility standards. Alleima produces wire in multiple configurations and even custom assemblies to suit novel device designs. An ablation catheter fitted with Alleima’s ultra-fine thermocouple wire will provide consistent, fast thermal feedback, ensuring the safety and efficacy of the treatment.
As ablation therapy becomes a mainstay in oncology, the demand for such high-performance sensors will only grow. For cancer patients, this means more treatment choices and gentler alternatives to traditional surgery. For device manufacturers, integrating cutting-edge thermocouple technology is key to staying ahead.
For an in-depth look at thermocouple wires and the engineering services that Alleima provides, download the whitepaper below.
