Abstract: A thin walled balloon formed in polymer tubing has a patterned metal layer on its outer surface, created by physical vapor deposition (PVD). The pattern is defined by a stencil mask assembled around the balloon, with the balloon inflated therein. The PVD occurs without deforming or degrading the polymer material of the balloon, by actively pulling heat away from the balloon a) by forming the stencil mask out of metal; b) by providing a metal heat conduction path away from the balloon to a heat sink, such as outside the vacuum chamber, and/or c) by flow of a cooling fluid within the balloon during the PVD process. Proper PVD process parameters are selected to minimize heat generation, such as having argon pressure in the range of 0.8 to 1.2 milli-torr and generating the plasma at a power of less than about 200 watts/ square inch of effective target surface area.

Abstract: A woven wire braid residing between a polymer inner lumen and a polymer outer lumen transmits control force in a catheter. After braiding the wires, the braid is plated with a metal, such as electroless nickel alloy deposited with a target thickness in a range of 250-1200 micro-inches. The metal plating joins the wires to each other at points of contact which torsionally stiffens the braid. At the same time, the metal plating leaves lengths of the wires unattached between the points of contact, permitting flexibility to the braid due to the unattached lengths between points of contact.