The World Health Organization estimates that over 600 million people suffer from lower back pain. Better treatments are needed to manage chronic pain conditions and improve patient health. As a result of this prevalence, Grand View Research estimates that the global pain management devices market will reach $13.1bn by 2030.
Radiofrequency ablation (RFA) is a minimally invasive therapy that uses targeted heat to interrupt pain signals. By avoiding surgery and focusing on the tiny nerve branches, RFA can relieve pain while leaving nearby healthy nerves intact.
RFA is used in a variety of painful conditions, including chronic pain from spinal arthritis, sacroiliac joint pain, and degenerative knee or shoulder arthritis. It can also be used to treat neck, back and peripheral nerve pain, trigeminal neuralgia, and cancer-related pain, as well as cardiac arrhythmias and tumour ablation.
In a typical RFA session, the patient lies under an X-ray or ultrasound while the physician numbs the skin and threads a hollow needle toward the identified nerve. A microelectrode is inserted through the needle, and once correctly positioned, radiofrequency current is sent through this electrode. The RF energy heats the nerve tissue to between 60-80 °C (140-175 °F), creating a controlled lesion that blocks the pain signal.
Other emerging technologies include pulsed RFA, which delivers short bursts of energy at lower temperatures (around 42°C/108 °F), aiming to modulate nerve function without causing permanent damage. This may be preferable in cases where lesioning poses a risk, such as neuropathic pain or near critical structures. Another alternative is cooled RFA, which circulates fluid around the electrode tip to create larger, more spherical lesions, particularly useful in deep tissues such as the sacroiliac joint.
Precision materials for reliable ablation outcomes
RFA requires an electrode needle, typically made from a fine, medical-grade conductive metal such as stainless steel or a platinum alloy. The electrode tip may be made of platinum‑iridium or gold-plated stainless steel for biocompatibility and conductivity, and inside the needle and probe, multiple ultra-thin wires carry current and sensor signals. The RFA system also includes the generator and ancillary gear, which produces the controlled radiofrequency current (usually around 400–500 kHz) and monitors power and impedance.
Too little heat and the lesion may fail to interrupt the nerve, while too much can damage adjacent structures. RFA probes therefore include thermocouples to provide the operator instant, precise feedback. Thermocouples are miniature temperature sensors, formed by joining two dissimilar metal alloys, providing real-time temperature readings at the tip of the probe to allow the generator to adjust the energy output dynamically.
These conductors must be insulated from each other and from the body. High-temperature polymer coatings are used so the wires remain thin and flexible but can tolerate the heat. Common insulations include poly-nylon and polyimides.
For companies seeking exceptional partners and solution providers, Alleima brings established material expertise, engineering know-how and vertical integration from melt to market to the development of components for radiofrequency ablation devices, including thermocouples and high-temperature insulation. From initial design through to advanced processing and precision manufacturing to finished, easy to integrate thermocouples,, Alleima’s comprehensive approach ensures seamless collaboration and tailored engineering.
With decades of experience in advanced metallurgy and polymer coatings, Alleima delivers thermocouples covering a wide temperature range using standard alloys (Type K, T, E, N) and specialised platinum–iridium alloys to handle outstanding temperature control. They offer ultra-fine thermocouple wires down to AWG50 (0.025 mm) and custom configurated alloys tailored to specific medical applications.
They also offer conductor materials that ensure biocompatibility, and durability under extreme conditions. Its expanding portfolio includes more than 200 medical-grade alloys, all manufactured with the precision needed for critical procedures such as nerve ablation.
To find out more, download the whitepaper below or visit the Alleima website.
