Abstract: Methods for making devices include providing a tubular member to be formed into a device, placing a removable sacrificial block material in the lumen of the tubular member and laser cutting the tubular member. A tubular member made from nickel-titanium alloy can be tightly adhered to a sacrificial sleeve utilizing the phase changes associated with nickel-titanium. A mandrel which includes an enlarged diameter section causes the workpiece to expand slightly within its elastic deformation range to dislodge islands from the workpiece. Such a mandrel could be formed from a tubular member which has a central lumen that can be used to deliver a pressurized medium to “blast” islands from the workpiece.

Abstract: Methods for making devices include providing a tubular member to be formed into a device, placing a removable sacrificial block material in the lumen of the tubular member and laser cutting the tubular member. A doping material can be added to the melted portion of the tubular member to promote the formation of brittle slag. A fixture can be used to hold a cut workpiece in order to ream sacrificial material from the surface of the workpiece. Pressurized gas can be supplied to the inner lumen of the tubular member to cause slag to form on the outside surface, rather than the inner surface, of the tubular member. A tubular member made from nickel-titanium alloy can be tightly adhered to a sacrificial sleeve utilizing the phase changes associated with nickel-titanium. A rotating mandrel can be placed within the lumen of the tubular member during laser cutting.