Abstract: An additive manufacturing system for producing a medical catheter or lead and a method thereof. The system including a heating cartridge defining an interior volume and at least one filament port. The system also including a heating element thermally coupled to the heating cartridge to heat the interior volume, a filament handling system to feed at least one filament through the at least one filament port, and a substrate handling system. The substrate handling system including a clamp to secure a portion of a substrate to be moved relative to the heating cartridge to apply a jacket to the substrate. In one or more embodiments, a subassembly is positioned on the substrate and has an electrode ring. The jacket printed to cover at least a portion of the subassembly and spaced apart from the electrode ring.

Abstract: Systems and methods of manufacturing 3D printed medical devices. The method includes feeding a first filament and a second filament into an interior cavity of a heating cartridge and melting each of the filaments on a substrate. The heating cartridge is then moved linearly and rotationally relative to the substrate to form a jacket including material from each of the first and second filaments. Further, rotating the substrate provides a uniform mixture and creates support rings between the filament materials within the structure of the jacket.

Abstract: Systems and methods for manufacturing elongate medical devices including internal components embedded between multiple jacket layers. The system including a heating cartridge, a heating element, a filament handling system, a substrate handling system, and a controller to feed and melt each of the filaments for forming the multiple jacket layers. The system may include a single heating cartridge adapted to make multiple passes to form a first and second jacket or multiple heating cartridges that sequentially form a first and second jacket.

Abstract: Systems and methods for manufacturing an elongate medical device including various surface features. The system including a heating cartridge, a heating element, a filament handling system, a substrate handling system, a controller, and one or more additional components adapted to form the surface features on the medical device. The heating element melts a filament material within the heating cartridge to form a jacket of the medical device and the one or more additional components engages the outer surface of the jacket to create surface features.

Abstract: Systems and methods for manufacturing elongate medical devices including internal components embedded between multiple jacket layers. The system including a heating cartridge, a heating element, a filament handling system, a substrate handling system, and a controller to feed and melt each of the filaments for forming the multiple jacket layers. The system may include a single heating cartridge adapted to make multiple passes to form a first and second jacket or multiple heating cartridges that sequentially form a first and second jacket.

Abstract: Implantable apparatus includes two or more alignable marker elements, and systems and methods for manufacturing such implantable apparatus, and methods to utilize such implantable apparatus. For example, the implantable apparatus may include a first alignable marker element and a second alignable marker element that may be used to ensure proper alignment with a target site.

Abstract: A transnasal transesophageal balloon catheter includes at least one compliant balloon attached to the external surface of the tubular body. An arrangement of structures extend away from the internal surface of the tubular body, and exposed probe guide surfaces on the structures form a lumen with a diameter of less than about 15 French (Fr) (5 mm) extending from the proximal end to the distal end of the tubular body and configured to slidably and rotatably receive the ultrasound probe. An arrangement of elongate fluid channels are interspersed with the structures. The fluid channels are in fluid communication with the lumen and transport a fluid between a fluid ingress port and a fluid egress port to at least partially inflate or deflate the balloon.

Abstract: Medical devices that provide for selected curve deflection in multiple planes such that three-dimensional shapes can be formed in the medical devices by placing a pull wire extending through the catheter in tension, as well as methods of manufacturing and using the medical devices. The medical devices may include selected portions in which the location of the pull wire changes circumferentially and/or radially to provide for the selected curve deflection. The medical devices may include, in addition to, or in place of changes in pull wire location, selected portions having exhibiting changes in rigidity to provide for the selected curve deflection.

Abstract: Medical devices that provide for selected curve deflection in multiple planes such that three-dimensional shapes can be formed in the medical devices by placing a pull wire extending through the catheter in tension, as well as methods of manufacturing and using the medical devices. The medical devices may include selected portions in which the location of the pull wire changes circumferentially and/or radially to provide for the selected curve deflection. The medical devices may include, in addition to, or in place of changes in pull wire location, selected portions having exhibiting changes in rigidity to provide for the selected curve deflection.

Abstract: Systems and methods of manufacturing 3D printed medical devices. The method includes feeding a first filament and a second filament into an interior cavity of a heating cartridge and melting each of the filaments on a substrate. The heating cartridge is then moved linearly and rotationally relative to the substrate to form a jacket including material from each of the first and second filaments. Further, rotating the substrate provides a uniform mixture and creates support rings between the filament materials within the structure of the jacket.

Abstract: Systems and methods for manufacturing elongate medical devices including internal components embedded between multiple jacket layers. The system including a heating cartridge, a heating element, a filament handling system, a substrate handling system, and a controller to feed and melt each of the filaments for forming the multiple jacket layers. The system may include a single heating cartridge adapted to make multiple passes to form a first and second jacket or multiple heating cartridges that sequentially form a first and second jacket.

Abstract: Systems and methods for manufacturing an elongate medical device including various surface features. The system including a heating cartridge, a heating element, a filament handling system, a substrate handling system, a controller, and one or more additional components adapted to form the surface features on the medical device. The heating element melts a filament material within the heating cartridge to form a jacket of the medical device and the one or more additional components engages the outer surface of the jacket to create surface features.