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It was reported that the balloon of a vascular catheter did not deflate.Staff had to puncture the balloon through the skin to deflate balloon.There were no patient injuries.A product evaluation was completed on the returned 120404f catheter.The customer reported of "did not deflate" was unable to be confirmed.As received, balloon was received ruptured.Balloon latex was released from proximal winding to check balloon edges.The edges did not appear to match at the rupture.The proximal winding had partially unraveled and slipped distal on the catheter tip.Both balloon and part of the proximal winding had slipped distal of the inflation ports.Balloon may be unable to deflate when slipped distal of the inflation ports.Distal winding was intact.No visible damage was observed from catheter body.A device history record review was completed and documented that device met all specifications upon distribution.An engineering evaluation was initiated to assess for any manufacturing related processes which could be correlated to the complaint.Based on the available information, there is no evidence that supports or confirms the failure mode is associated to a manufacturing or design defect.As part of the manufacturing process, balloon and winding inspections are performed on 100% of catheters.Per the ifu, "balloon rupture and catheter separation as a result of excessive pull force applied to remove adherent material are the most frequent causes of reported failures", and, "to minimize the risk of vessel damage, balloon rupture, or tip detachment, do not exceed the maximum recommended inflation and pull force for each size catheter." additionally, the ifu states "the possibility of balloon rupture must be taken into account when considering the risks involved in any embolectomy procedure." complaint histories for all reported events are reviewed against trending control limits on a monthly basis and any excursions above the control limits are assessed and documented as a part of the monthly review.
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