3D Printed Catheter Multi-Plane Articulation via Offset Pull Wire
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Solution Overview
Problem
Existing medical catheters face challenges in achieving consistent 3D shapes due to limitations in manufacturing processes, such as conventional extrusion, which struggle with multi-plane articulation and shape retention.
Innovation Solution
The use of additive manufacturing to create 3D printed medical devices, such as catheters, with multi-plane articulation capabilities by incorporating a pull wire that changes location relative to the catheter axis, allowing for selected curve deflection in multiple planes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional extrusion manufacturing is used, then manufacturing simplicity is maintained, but multi-plane articulation and consistent 3D shape capability are limited
Solution Approach 1:
The pull wire is configured to move dynamically within the catheter body along a predetermined path, allowing the catheter to articulate in multiple planes. This dynamic positioning capability enables the catheter to change its shape and orientation in response to pulling forces applied at different locations, achieving multi-plane articulation without complex manufacturing processes.
Solution Approach 2:
The invention adds a spatial dimension to the pull wire configuration by positioning it at an offset from the catheter axis and allowing it to move along a three-dimensional path through the catheter body. This dimensional approach enables articulation in multiple planes (X-Y, X-Z, Y-Z planes) rather than being constrained to a single plane, achieving complex 3D shaping capability.
2Device complexity
If a single pull wire is used for articulation, then device complexity is reduced, but achieving consistent 3D shape and multi-plane deflection becomes difficult
Solution Approach 1:
The pull wire is pre-configured within the catheter body along a predetermined path that is established during manufacturing. This preliminary positioning ensures that when force is applied, the catheter deflects in the intended direction and achieves the desired 3D shape consistently. The pre-set path geometry guarantees shape consistency without requiring multiple pull wires.
Solution Approach 2:
The pull wire acts as an intermediary element that translates applied force into controlled catheter deflection. By positioning the pull wire at an offset from the axis and routing it through a predetermined path, it mediates the relationship between applied tension and resulting catheter shape, enabling consistent multi-plane articulation with a single wire.
3Adaptability or versatility
If the pull wire is positioned at the axis, then structural symmetry is maintained, but multi-plane articulation capability is reduced
Solution Approach 1:
The pull wire is deliberately positioned asymmetrically at an offset from the catheter axis rather than at the center. This asymmetric positioning is essential for achieving multi-plane articulation, as it creates leverage and moment arms that enable deflection in multiple directions. The asymmetry allows the single pull wire to control articulation in X-Y, X-Z, and Y-Z planes, providing articulation freedom that symmetric positioning cannot achieve.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the formation of complex three-dimensional shapes in catheters, improving their navigability through tortuous paths in the body while maintaining desired shape characteristics.
Implementation Method 1
The use of additive manufacturing to create 3D printed medical devices, such as catheters, with multi-plane articulation capabilities
Implementation Method 2
the pull wire is configured to deflect the catheter body in two or more planes when pulled in a direction away from the anchor
Data Source
AI summary
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.