Company insight
Configurations range from bifilar (two wires) to multifilar set-ups, which may include redundant pairs or additional conductors for multifunctional use. Some wires come pre-packaged with encapsulated junctions, simplifying integration and ensuring consistent thermal response.
There are several applications across medical specialities: ■ Cardiac ablation: Thermocouples are integral to radiofrequency (RF) ablation catheters used to treat arrhythmias such as tachycardia and atrial fibrillation. Embedded in the catheter tip, they monitor tissue temperature in real time, allowing RF generators to modulate power and prevent overheating. In cryoablation, thermocouples ensure the tissue reaches and maintains the target freezing temperature, avoiding ineffective lesions or tissue damage. Emerging modalities like pulsed field ablation (PFA) also benefit from thermocouple monitoring. Though PFA aims to avoid thermal injury, incidental heating can occur. Thermocouples help detect and mitigate these risks.
■ Renal denervation and metabolic therapies: In catheter-based treatments for resistant hypertension, thermocouples regulate energy delivery during sympathetic nerve ablation in the renal arteries. They help prevent overheating and ensure precise targeting, especially in systems using ultrasound energy. Duodenal mucosal resurfacing (DMR), a novel therapy for
type 2 diabetes and non-alcoholic fatty liver disease (NAFLD), uses thermal ablation to regenerate the duodenal lining. Thermocouples provide accurate feedback to ensure safe and effective energy application.
■ Oncology and tumour ablation: Thermocouples are widely used in interventional oncology for RF, cryo, microwave and ultrasound ablation. They provide feedback to control energy delivery, ensuring complete tumour destruction while minimising damage to surrounding tissues. Cryoablation probes often include multiple sensors to monitor the extent of freezing, while microwave and high- intensity focused ultrasound (HIFU) systems rely on thermocouples for real-time thermal control.
■ Pain management and neuromodulation: RF neurotomy for chronic pain conditions such as facet joint arthritis and trigeminal neuralgia depends on thermocouples to create accurate heat lesions. These sensors prevent excessive heating and collateral damage, enhancing both safety and efficacy.
■ Gynaecological therapies: Endometrial ablation procedures use thermocouples to monitor and regulate temperature during RF, cryotherapy or heated fluid treatments. They help maintain uniform ablation and activate safety shut-offs if temperatures exceed safe thresholds.
■ Critical care and diagnostic equipment: Thermocouples are embedded in ventilators, incubators, sterilisers and dialysis machines to monitor and control temperature. In neonatal care, they help maintain thermoneutral environments. In imaging systems like MRI and CT scanners, they prevent overheating of critical components. Laboratory equipment also uses thermocouples to ensure safe storage conditions for blood, vaccines and reagents. In hyperthermia therapy, thermocouples monitor treatment area temperatures to optimise cancer care.
Thermocouples are quietly powering the future of healthcare.
Dr Cacie McDorman, global product manager wire technologies, Alleima
Market trends and growth outlook
The global market for medical thermocouple wires is projected to grow from $500m in 2025 to approximately $850m by 2033, at a CAGR of 7%. This growth is driven by the rise of minimally invasive procedures and the increasing prevalence of chronic diseases.
Leadership in
thermocouple innovation Collaborating closely with world-leading OEMs, Alleima delivers integrated precision-calibrated thermocouples that advance innovation and enhance patient care outcomes worldwide.
“Our thermocouple wires span from
AWG24 (0.5104mm) to ultrafine AWG50 (0.0205mm) and are available in various configurations and insulation types,” says Dr Cacie McDorman, global product manager wire technologies at Alleima’s medical unit. “Our wires also meet or exceed standards like ASTM E230 and ANSI MC 96.1, ensuring reliability in critical healthcare environments. “We manufacture traditional alloys such as Types K, T, E and N, and process precious metals including platinum and its alloys (Pt10Ir, Pt20Ir). Our medical alloy portfolio spans over 200 metals and alloys, enabling bespoke solutions tailored to the rigorous demands of medical applications. We also make custom-made alloys on request, specific to our customers’ needs.” Thermocouple wires may be small, but their impact on medical safety and precision is immense. From cardiac care to oncology, and from pain management to critical diagnostics, these sensors enable clinicians to deliver targeted, effective treatments with confidence. As medical technology continues to advance, thermocouples will remain a cornerstone of innovation, quietly powering the future of healthcare. ●
www.alleima.com/thermocouples
www.medicaldevice-developments.com 89
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