Reprocessing of single-use intravascular catheters is a common practice in public health services and hospitals. The determination of safe number of reprocessing cycles before the catheter integrity becomes compromised has been a priority issue. The present paper addresses the evaluating molecular and micro-structural integrity of reprocessed cardiac angiographic catheters. The Fourier Transform Infrared Spectroscopy and Scanning Electron Microscopy were carried out to elucidate morphological changes. The tensile test was performed on catheters to examine changes in bulk characteristics. In this work, samples of catheters were reprocessed until nine times and sterilized by hydrogen peroxide plasma. It was observed that the number of hydrogen-bonded carbonyls groups increased in 0.05 u.a. (p < 0.001) after each reprocessing cycle. The spectra indicated degradation products included acids, esters, alcohols, and small amounts of other products containing a carbonyl functional group. The micrographs revealed that only after the fourth reprocessing cycle the effect increased in the surface roughness was more pronounced. On the other hand, after each reprocessing cycle and as consequence of extensive aging of polyamide/polyurethane blends of the catheters surface, it was observed that the micro-fissures, micro-scratches and micro-pores increased in quantity and length. The mechanical test proved that the Young modulus increased in average 3.26 MPa (p = 0.0003) at increasing number of reprocessing cycles, also suggestive of crosslinking in this material. (C) 2009 Elsevier B.V. All rights reserved.