One catheter with attached monoject 1.5 cc limited volume syringe and two three-way stopcocks with pressure tubes was returned for evaluation with original opened pouch and tray.No tyvek or introducer was returned.A kink with uv bonding partial separation was observed on the catheter body at 25 cm proximal from the catheter tip.Protrusion on the catheter body was observed at 61 cm proximal from the catheter tip.Stiff material was visible inside the catheter body between 25 cm and 61 cm proximal from the catheter tip.A lab sample of 0.021" guidewire (as recommended in the ifu) was inserted in the distal lumen from hub to tip and the guidewire stuck at 61 cm proximal from the tip.This guidewire was then inserted in the distal lumen from tip to hub and the guidewire stuck at 25 cm proximal from the tip.The areas were the guidewire became stuck matched the location of the kink and the protrusion on the catheter body.No other visible damage to the catheter body, balloon, or returned syringe was observed.All through lumens were patent without any leakage or occlusion.The balloon inflated clear, concentric and remained inflated for more than 5 minutes without leakage.No visible inconsistency was observed on eeprom data.Further examination of the catheter included placing the catheter on a bench and a stylet wire was used to push the wire like material out of the distal lumen.The od of the wire like material was measured at 0.023" and the length was 35.5cm.The material was sent to chemistry for energy dispersive x-ray spectroscopy (eds) testing.Results indicated the presence of the following elements in the wire like material; titanium and nickel.Further examination of the wire like material appeared to be wire used during the manufacturing process.Balloon inflation test was performed using returned syringe with 1.5 cc air.Visual examination was performed under microscope at 20x magnification and with the unaided eye.A device history record review was completed and documented that device met all specifications upon distribution.Customer report of bent lumen issue was confirmed and in addition a wire like material was found inside the distal lumen during evaluation.An investigation has been initiated to consider any potential manufacturing factors that may have contributed to this complaint and implement any necessary corrective actions.
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