EPA ban on methylene chloride pushes manufacturers toward laser wire stripping

The U.S. Environmental Protection Agency has issued its final rule regulating methylene chloride, a chemical solvent long used in manufacturing and fine wire stripping. The ban on most commercial uses is due to come into effect in the United States in April 2026. The decision is prompting medical device makers to turn to laser-based technology as a cleaner and safer alternative.

The United States Environmental Protection Agency (EPA) announced in April 2024 a sweeping ban on most uses of methylene chloride, a chemical long used in industrial applications including precision wire stripping. The move, described by the agency as a necessary step to protect workers and consumers from “unreasonable risk of injury to human health,” will effectively phase out nearly all commercial and industrial uses of the solvent by 28th April 2026.

Methylene chloride, also known as dichloromethane, has been linked to serious health hazards including cancer, liver toxicity, and fatal exposure incidents. While consumer products containing the solvent were restricted in 2019, the latest ruling extends prohibitions to nearly every remaining use, with only a handful of tightly controlled industrial exemptions.

The new regulation has major implications for manufacturers that rely on fine wire stripping processes, particularly in the medical device industry, where ultra-thin insulated wires are used in catheters, sensors and implantable devices. For decades, methylene chloride and similar solvents have been used to remove microscopic insulation layers from these wires, but with the chemical now effectively banned, companies are being forced to find safer alternatives.

A key technology rapidly gaining ground in the medical sector is laser wire stripping, which removes insulation using focused laser energy instead of chemicals or mechanical blades. The method is entirely solvent-free, non-contact, and leaves no residue – qualities that are particularly valuable in cleanroom manufacturing environments. The process also offers exceptional precision, with the ability to target insulation layers just a few microns thick.

Industry specialists say the EPA’s decision has accelerated a shift that was already underway toward cleaner, automated manufacturing methods. “Medical device manufacturers were already under pressure to reduce chemical use, this ban simply brings that change to the top of everyone’s agenda.” said Dr Peter Dickinson, Chairman and CTO at Spectrum Technologies, which develops laser wire stripping systems.

The transition to laser-based processes isn’t just about compliance. For manufacturers, it also promises greater process control, repeatability, and traceability – all key priorities in highly regulated medical production. “The technology has matured to the point where laser stripping is not only safer but also more consistent and scalable,” Dr Dickinson added.

Spectrum Technologies will be launching its latest SIENNA laser processing system, specifically designed for stripping fine and ultra-fine wire for medical applications at MEDICA 2025, the international medical technology trade fair taking place in Düsseldorf this November. Visitors can find the company at Hall 16, Stand J03, Location 12, where live demonstrations will show how laser stripping can replace solvent-based methods and improve precision and safety.

The U.S. ban could set a precedent for further restrictions worldwide, further pushing the medical industry toward chemical-free manufacturing technologies.

For now, the message from regulators and industry alike is clear: the era of solvent-based wire stripping is ending, and laser technology is set to take its place.

Visit Spectrum Technologies at MEDICA 2025 – Hall 16, Stand J03, Location 12 (Welsh Government Pavilion).