Abstract: An implantable pulse generator includes a core assembly, a seal plug, and an outer layer overmolded over the core assembly adjacent the seal plug. The core assembly defines a core hole extending through the core assembly from a core interior to a core outer surface. The core hole has a hole outer portion and a hole inner portion. A first diameter of the hole outer portion is less than a second diameter of the hole inner portion. The seal plug is positioned in the core hole and has a plug outer portion aligned with the hole outer portion and a plug inner portion aligned with the hole inner portion. A third diameter of the plug outer portion is less than a fourth diameter of the plug inner portion. The outer layer leaves a top of the seal plug exposed.

Abstract: A method includes providing a mold defining a mold cavity for receiving material to be molded into a molded part, positioning an insert at least partially in the mold such that a portion of the insert defines a portion of the mold cavity, and injecting the material into the mold cavity to substantially fill the mold cavity to form the molded part. The molded par can then be removed from the mold and the insert can be removed from the molded part. The mold can include silicone and the insert can include polyoxymethylene.

Abstract: An implantable pulse generator includes a core assembly, a seal plug, and an outer layer overmolded over the core assembly adjacent the seal plug. The core assembly defines a core hole extending through the core assembly from a core interior to a core outer surface. The core hole has a hole outer portion and a hole inner portion. A first diameter of the hole outer portion is less than a second diameter of the hole inner portion. The seal plug is positioned in the core hole and has a plug outer portion aligned with the hole outer portion and a plug inner portion aligned with the hole inner portion. A third diameter of the plug outer portion is less than a fourth diameter of the plug inner portion. The outer layer leaves a top of the seal plug exposed.

Abstract: An implantable pulse generator includes a core assembly, a seal plug, and an outer layer overmolded over the core assembly adjacent the seal plug. The core assembly defines a core hole extending through the core assembly from a core interior to a core outer surface. The core hole has a hole outer portion and a hole inner portion. A first diameter of the hole outer portion is less than a second diameter of the hole inner portion. The seal plug is positioned in the core hole and has a plug outer portion aligned with the hole outer portion and a plug inner portion aligned with the hole inner portion. A third diameter of the plug outer portion is less than a fourth diameter of the plug inner portion. The outer layer leaves a top of the seal plug exposed.

Abstract: An implantable pulse generator includes a core assembly, a seal plug, and an outer layer overmolded over the core assembly adjacent the seal plug. The core assembly defines a core hole extending through the core assembly from a core interior to a core outer surface. The core hole has a hole outer portion and a hole inner portion. A first diameter of the hole outer portion is less than a second diameter of the hole inner portion. The seal plug is positioned in the core hole and has a plug outer portion aligned with the hole outer portion and a plug inner portion aligned with the hole inner portion. A third diameter of the plug outer portion is less than a fourth diameter of the plug inner portion. The outer layer leaves a top of the seal plug exposed.

Abstract: A method includes providing a mold defining a mold cavity for receiving material to be molded into a molded part, positioning an insert at least partially in the mold such that a portion of the insert defines a portion of the mold cavity, and injecting the material into the mold cavity to substantially fill the mold cavity to form the molded part. The molded par can then be removed from the mold and the insert can be removed from the molded part. The mold can include silicone and the insert can include polyoxymethylene.

Abstract: An implantable pulse generator includes a device housing containing pulse generator circuitry and a header molded to the device housing. The header can be formed of an epoxy header material. A header component can have a first part molded in the header material to fix the header component to the header at a surface of the header and a second part extending out of the header material.

Abstract: Systems and methods for implantable medical devices and headers are described. In an example, an implantable medical device includes a device container including an electronic module within the device container. A header core includes a bore hole portion and at least two electronic connection features disposed within the bore hole portion. The bore hole portion includes at least one cavity configured to allow placement of at least one of the electronic connection features within the bore hole portion. The at least two electronic connection features are electrically coupled to the electronic module within the device container. The header core is configured to allow location of the at least two electronic connection features in a selected configuration within the bore hole portion. A header shell is disposed around the header core and attached to the device container.

Abstract: Systems and methods for implantable medical devices and headers are described. In an example, an implantable medical device includes a device container including an electronic module within the device container. A header core includes a bore hole portion and at least two electronic connection features disposed within the bore hole portion. The bore hole portion includes at least one cavity configured to allow placement of at least one of the electronic connection features within the bore hole portion. The at least two electronic connection features are electrically coupled to the electronic module within the device container. The header core is configured to allow location of the at least two electronic connection features in a selected configuration within the bore hole portion. A header shell is disposed around the header core and attached to the device container.