Electroplated Catheter Tips for High-Volume Manufacturing
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Solution Overview
Problem
Current methods for manufacturing radiofrequency ablation catheter tips are time and labor intensive, making them costly and difficult to scale for mass production due to the need for individual machining of irrigation holes and shell formation.
Innovation Solution
A method involving electroplating a conductive material over removable inserts or molds to create catheter tips with a dome-like shape, including the selective positioning of irrigation holes, and subsequent electropolishing to produce multiple catheter tips efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual machining is used to create irrigation holes and shell for each catheter tip, then manufacturing precision is maintained, but productivity is reduced and production costs increase
Solution Approach 1:
The catheter tip manufacturing process is segmented into two distinct phases: (1) mass production of electroplated shells with integrated irrigation holes through simultaneous electroplating of multiple inserts, and (2) individual customization of each shell with electrodes and radiofrequency conductors. This segmentation allows high-volume production of standardized components while preserving the ability to customize each final device, thereby resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The electroplated shells with irrigation holes are produced in advance through a preliminary mass production process using simultaneous electroplating of multiple inserts. This preliminary action creates standardized, precision-manufactured components that can be stored and later assembled with customized electrodes and conductors, eliminating the need for time-consuming individual machining of each catheter tip while maintaining manufacturing precision.
2Manufacturing precision
If individual machining is used for each catheter tip, then manufacturing precision is maintained, but production time increases
Solution Approach 1:
Multiple inserts are combined into a single electroplating fixture, allowing simultaneous electroplating of multiple catheter tip shells with integrated irrigation holes. This merging of operations reduces production time by producing multiple precision components in parallel rather than sequentially, while the electroplating process itself maintains manufacturing precision through controlled deposition.
Solution Approach 2:
The traditional mechanical machining process for creating irrigation holes and shaping catheter tips is replaced with an electrochemical electroplating process. This substitution eliminates time-consuming mechanical operations while maintaining or improving manufacturing precision through controlled electrochemical deposition, significantly reducing production time per catheter tip.
3Ease of manufacture
If traditional machining methods are used, then manufacturing control is maintained, but device complexity increases due to multiple processing steps
Solution Approach 1:
The electroplating process is designed to perform multiple functions simultaneously: shaping the catheter tip shell, creating irrigation holes through the insert structure, and depositing conductive material in a single integrated operation. This multi-functionality reduces the number of manufacturing steps compared to traditional sequential machining operations, simplifying the overall manufacturing process while maintaining ease of manufacture through a standardized electrochemical process.
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 high-volume manufacturing of catheter tips with improved productivity and reduced production costs while maintaining the functionality of the distal end, allowing for efficient production of catheter tips with low impedance at low frequencies.
Implementation Method 1
electroplating a conductive material over an insert including a negative to a domelike shape thereby forming a shape of the catheter tip including a dome with the domelike shape
Implementation Method 2
electropolishing the catheter tip
Data Source
AI summary
A method of manufacturing a catheter tip by electroplating a conductive material over an insert comprising a negative to a domelike shape thereby forming a shape of the catheter tip comprising a dome with the domelike shape, selectively positioning a plurality of irrigation holes between outer and inner surfaces of the catheter tip, removing the insert thereby leaving the catheter tip and the plurality of irrigation holes, and electropolishing the catheter tip. In other examples, the insert is not removed and instead the step of electroplating causes the insert to be encapsulated with the conductive material thereby forming the catheter tip.