Patrick Daly has more than 20 years of experience in medical device extrusion, with deep expertise in polymer processing and catheter-related applications. He specializes in the development of complex tubing solutions, including multi-lumen and co-extrusion designs, and works closely with engineering teams to translate design requirements into manufacturable extrusion architectures.
Patrick is particularly focused on how extrusion architecture influences catheter system performance and manufacturability, helping teams anticipate challenges that often emerge later in development. His experience spans both development and production environments, with an emphasis on consistency, scalability, and real-world performance.
Catheter development challenges often appear during verification or scale-up, but their root causes frequently trace back to earlier engineering decisions. Architecture choices, material assumptions, tolerance stackups, and extrusion design all interact to shape device performance and manufacturability long before teams fully understand their impact.
This session explores the hidden complexity inside catheter systems and how early decisions, including those that define extrusion profiles, influence performance, manufacturability, and program timelines. Drawing on real-world experience, panelists will share practical approaches for aligning design intent with manufacturing reality to reduce risk and move programs from concept to clinic more efficiently.