Braided Stent Geometry With Consistent Angles Across Diameters

The patent applies preliminary action by pre-cutting wire segments to the exact length needed for each stent before braiding begins. This eliminates the need to feed continuous wire from a spool and trim excess at the end, as each wire segment is precisely sized in advance. The wire segments are loaded onto the mandrel ready-to-braid, preventing material waste while maintaining production efficiency.

The patent segments the continuous wire feed into discrete pre-cut wire segments, each corresponding to the precise length required for a single stent. This segmentation allows multiple stents to be formed from separate wire segments rather than trimming a continuous wire, thereby eliminating material waste while preserving the ability to produce multiple stents efficiently.

The patent applies preliminary action by pre-positioning wire segments on the mandrel with their ends aligned precisely at the mandrel end before braiding begins. This pre-alignment prevents wire shifting during the braiding process, maintaining consistent braiding angles throughout. The wires are gathered and secured in their final positions beforehand, eliminating the need for continuous adjustment during braiding.

The patent introduces an intermediary mechanism in the form of a wire gathering and alignment system at the mandrel end. This intermediary structure holds multiple wire segments in precise alignment before they enter the braiding zone, preventing lateral shifting and maintaining consistent braiding angles. The intermediary device acts as a mediator between the wire feed system and the braiding process, ensuring geometric precision.

The patent applies local quality by using wire segments with locally varied properties - each wire segment can have different lengths, orientations, or configurations tailored to specific regions of the stent. This allows flared, flanged, or tapered portions to be created with precise local control while maintaining overall braiding angle consistency through the use of pre-positioned segments rather than continuous wire feeding.

The patent applies preliminary action by pre-configuring wire segments with specific geometries and orientations before braiding. Wire segments intended for flared or tapered regions are pre-shaped or pre-oriented to achieve the desired local geometry. This preliminary preparation allows complex varied-diameter stent configurations to be achieved while maintaining precise braiding angle control through the use of pre-positioned, pre-configured wire segments.