Abstract: A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.

Abstract: A part ejector is shown and described wherein a machined part in a CNC lathe is ejected from a spindle of the lathe by means of an air pressure differential. The part ejector includes inner and outer tubes that are coupled to, and aligned with a spindle collet. Machined parts are received within the inner tube and a pin tool moves a pin into the inner tube to pneumatically seal the inner tube and push a machined part past one or more air ports that pneumatically connect the inner tube with an air channel located between the inner and outer tubes. Pressurized air is applied to the air channel and the pin is partially retracted to uncover the air ports thus allowing the pressurized air to enter the inner tube and eject the machined part out.

Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.

Abstract: Woven structures and associated systems for weaving such structures are disclosed. Some disclosed innovations pertain to braided structures, such as braided wire structures, with axially asymmetric woven structures (or “directional meshes”) being examples. Other innovations disclosed herein pertain to methods of manufacturing woven structures, with automated methods of braiding directional meshes being examples. Some directional mesh embodiments can be configured and used as energizable electrodes for electrosurgical therapies, for example, bipolar vaporization therapies.

Abstract: An implantable medical device that includes a first molded portion and a second molded portion fusion bonded to the first molded portion at an interface. The molded portions each are based on a moldable plastic material. A component, e.g., an electrical component, for the implantable device has at least one section disposed at the fusion-bonded interface of the first molded portion and the second molded portion so that the electronic component is fusion bonded to one or both portions at the interface.

Abstract: A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.

Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.

Abstract: An implantable medical device that includes a first molded portion and a second molded portion fusion bonded to the first molded portion at an interface. The molded portions each are based on a moldable plastic material. A component, e.g., an electrical component, for the implantable device has at least one section disposed at the fusion-bonded interface of the first molded portion and the second molded portion so that the electronic component is fusion bonded to one or both portions at the interface.

Abstract: The present invention provides a continuous powder extrusion method for making an article having a profile including an outer shape and optionally including one or more inner hollows. One or more bulk material powders and one or more binders are provided, and the bulk material powders and the binders are mixed to form a mixture. A die is provided, the die optionally including a mandrel having one or more shapes. The mixture is extruded through the die and the optional mandrel to produce a green form. The green form is debound to produce a brown form and the brown form is sintered to produce a densified form. The densified form is optionally processed using thermal, mechanical, and/or thermomechanical processing to produce a wrought form. The densified or wrought form is optionally cut to a length and/or finished using traditional metal finishing processes.

Abstract: The present invention is a method for measuring and calculating tensile elongation of ductile metals on small diameter specimens. The method includes marking a tensile specimen with a pattern of gage markings at predetermined intervals. The tensile specimen is pulled to failure and then fitted together at the fracture. Distances between corresponding markings straddling the fracture are measured extending progressively outward from the fracture. From the measurements, elongation as a function of gage length is determined. End point elongation values (i.e., elongation at zero or near zero and infinite or very long gage lengths) are also determined. Determined elongations are scaled to reflect the values that would have been generated on a standard 0.5 inch diameter specimen. Based on the scaled elongation as a function of gage length and the end point elongation values, a value of elongation can be determined that represents a material property for FEA modeling the plastic strain behavior of a device.

Abstract: An apparatus and method are provided for simultaneously electropolishing a plurality of metallic stents. A plurality of elongated members on the apparatus are movably engaged with a plate such that movement of the plate relative to the elongated members causes each of the elongated members to rotate on its respective longitudinal axis when immersed in an electrolytic solution. A continuous cathode is located in close proximity to each of the elongated members when they are immersed in the electrolytic solution.

Abstract: The present invention includes a method of making a metal injection molded article and the metal injection molded article. The method includes mixing metal powders and a binder to form a mixture. The metal powders include a bulk material and at least one radiopaque material. The mixture is injected into a mold and processed into a green part. The green part is debound to form a brown part. The brown part is sintered to create a completed article. The completed article includes a metal alloy that includes the bulk material and a dispersion of the at least one radiopaque material substantially independent of the metal alloy.

Abstract: The present invention is a method for measuring and calculating tensile elongation of ductile metals on small diameter specimens. The method includes marking a tensile specimen with a pattern of gage markings at predetermined intervals. The tensile specimen is pulled to failure and then fitted together at the fracture. Distances between corresponding markings straddling the fracture are measured extending progressively outward from the fracture. From the measurements, elongation as a function of gage length is determined. End point elongation values (i.e., elongation at zero or near zero and infinite or very long gage lengths) are also determined. Determined elongations are scaled to reflect the values that would have been generated on a standard 0.5 inch diameter specimen. Based on the scaled elongation as a function of gage length and the end point elongation values, a value of elongation can be determined that represents a material property for FEA modeling the plastic strain behavior of a device.

Abstract: An article having a nickel-titanium alloy and a homogeneous dispersion of discrete particles. The discrete particles are substantially free of nickel and titanium. A method of making the article includes melting a substantially equiatomic composition of nickel and titanium to form an alloy and dispersing a discrete particle in the alloy to form an ingot. The melting and dispersing are performed at a temperature above the alloying temperature of the composition and below the melting temperature of the discrete particle. The ingot is hot worked to form a processed ingot. The processed ingot is cold worked and annealed to form the article.

Abstract: An article made of a medical alloy having two or more alloying elements, and a uniform dispersion of discrete particles, which are substantially free of the two or more alloying elements. A method of making the article includes melting a composition having two or more alloying elements to form an alloy and dispersing a discrete particle in the alloy to form an ingot. The melting and dispersing are performed at a temperature above the alloying temperature of the composition and below the melting temperature of the discrete particle. The ingot is hot worked to form a processed ingot. The processed ingot is cold worked and annealed to form the article.

Abstract: Various wires and methods of making the same are disclosed. In one aspect, a wire is provided that includes a core and a tube around the core. The tube is composed of an alloy containing about 33 to 37% nickel, about 31.5 to 39% cobalt, about 9 to 10.5% molybdenum, and about 19 to 21% chromium. The wire has an ultimate tensile strength of about 150 to 250 kpsi, an amount of cold work following a final anneal and a torsional ductility of greater than about 6 turns-to-failure per inch of the wire.

Abstract: A self-configurable, adaptable and programmable (hereinafter “CAP”) I/O bus (15) is provided in a digital computer (11) to establish compatibility between the input/output bus of computer (11) and an incompatible input/output bus of an external module (12). Computer (11) includes a field programmable gate array (FPGA) (31) for translating the bus configuration used by module (12) to that employed by computer (11). Two preselected CAP I/O Bus conductors (17, 18) pass an identification number from the module (12) to computer (11) that points to the location of the information necessary to compatibly configure FPGA (31). This information, which includes a bus logic FPGA image file and a device driver, and may include a protocol driver, may be found in one of several locations, including onboard computer (11) in memory, onboard module (12), or at an external site such as a server (28) accessible via the Internet.