The difference between butt weld and overlap weld

Two common methods of catheter tube welding are butt weld and overlap weld, and there are the following main differences between them:

Joining form:

Butt weld: Direct butt welding of catheter tubes ends. The cross section after welding is flat.

Overlap weld: The ends of the catheter tubes are overlapped and welded. The welds are overlapping.

Strength characteristics:

Butt weld: The welding strength is high and can reach the strength of the parent material.

Overlap weld: The welding strength is slightly lower than the strength of the parent material, but still has high strength.


Butt weld used for catheter tubes that bear large axial or bending forces. Butt Weld can achieve the same strength as the catheter tube itself, ensuring that the catheter can function normally in a complex human environment. Such as: coronary stent catheter, angiography catheter, renal dialysis catheter, gastrointestinal catheter.

Overlap weld used for catheter tubes that bear small axial or bending forces. The weld shape of Overlap Weld is more conducive to insertion and the smoothness of the catheter surface, thereby improving patient comfort. Such as intravenous infusion catheters, drainage catheters, urethral catheters, chest drainage catheters.

Manufacturing difficulty:

Butt weld: It requires high end face butt welding accuracy and is more difficult to weld.

Overlap weld: It is relatively simple to manufacture and has low end face butt welding requirements.

In short, butt weld and overlap weld each have their own characteristics and applications, and engineers need to choose the appropriate welding method according to the specific situation.

Send us your ideas and we’ll get in touch with you within 24H!

Share this post!

Request A Quote