Medical devices and methods of making the same
Medical devices, such as stents, and methods of making the devices are disclosed. In some embodiments, the devices are made using a laser forming process.
1 . A method of making a medical device, comprising:
melting a first material on a substrate; and
solidifying the material,
wherein the solidified first material forms a portion of the medical device.
2 . The method of claim 1 , wherein the first material is melted by a laser.
3 . The method of claim 2 , further comprising moving the laser or the substrate relative to each other.
4 . The method of claim 1 , further comprising forming a layer of the first material surrounding the substrate.
5 . The method of claim 1 , further comprising melting a second material on the first material.
6 . The method of claim 5 , wherein the second material is more radiopaque than the first material.
7 . The method of claim 6 , wherein the second material comprises a material selected from the group consisting of tantalum, platinum, iridium, palladium, tungsten, gold, ruthenium, molybdenum, and rhenium.
8 . The method of claim 6 , wherein the first material comprises stainless steel.
9 . The method of claim 5 , wherein the second material is less radiopaque than the first material.
10 . The method of claim 1 , further comprising delivering the first material to the substrate.
11 . The method of claim 10 , wherein the first material is in the form of a powder.
12 . The method of claim 1 , further comprising changing the size of the powder.
13 . The method of claim 10 , wherein the first material is sprayed on the substrate.
14 . The method of claim 1 , wherein the first material comprises a plurality of different elements.
15 . The method of claim 1 , further comprising separating a portion of the substrate from the first material.
16 . The method of claim 1 , wherein the first material is in the form of a powder.
17 . The method of claim 1 , comprising forming the first material into a tubular member.
18 . The method of claim 17 , further comprising forming the tubular member into a stent.
19 . The method of claim 1 , wherein the first material comprises an alloy.
20 . The method of claim 1 , further comprising changing the composition of the first material.
21 . The method of claim 1 , wherein the first material is melted by a laser, and further comprising changing the operating conditions of the laser during melting of the first material.
22 . The method of claim 1 , further comprising placing an elongated second material more radiopaque than the first material on the solidified first material.
23 . The method of claim 1 , wherein the second material is wrapped around the first material.
24 . A method of making a stent, comprising:
delivering a first material to a substrate;
melting the first material with a laser onto the substrate;
solidifying the first material;
delivering a second material to the substrate;
melting the second material with the laser onto the first material; and
solidifying the second material,
wherein the first and second materials form a portion of the stent.
25 . The method of claim 24 , wherein the first and second materials define a tubular member.
26 . The method of claim 25 , further comprising forming the tubular member into the stent.
27 . The method of claim 24 , wherein the second material more radiopaque than the first material.
28 . The method of claim 24 , wherein the second material is less radiopaque than the first material.
29 . The method of claim 24 , further comprising delivering a third material to the substrate, and melting the third material onto the second material.
30 . The method of claim 29 , wherein the third material is substantially the same as the first material.
31 . A stent, comprising a layer of material having an average of at least about nine grains per unit area.
32 . The stent of claim 31 , wherein the layer has an average of at least about twelve grains per unit area.
33 . The stent of claim 31 , wherein the layer has an average of at least about sixteen grains per unit area.
34 . The stent of claim 31 , wherein the layer has a gradient of grain sizes along the thickness of the stent.
35 . A stent, comprising a layer of material having an average grain size less than about ten microns.
36 . The stent of claim 35 , wherein the average grain size is less than about eight microns.
37 . The stent of claim 35 , wherein the average grain size is less than about six microns.
38 . The stent of claim 35 , wherein the layer has a gradient of grain sizes along the thickness of the stent.
39 . A stent, comprising a layer of material having a gradient of grain sizes along the thickness of the stent.
40 . A stent, comprising a layer of material having a gradient of composition along the thickness of the stent.
41 . A method of making a medical device, comprising:
delivering particles of a first material toward a substrate;
applying energy to the particles to form a layer of the first material on the substrate; and
using the layer to form the medical device.
42 . The method of claim 41 , wherein the energy is applied with a laser.
43 . The method of claim 42 , wherein the energy is applied simultaneously with delivery of the particles.
44 . The method of claim 41 , comprising melting at least a portion of the particles with the energy.
45 . The method of claim 41 , comprising changing the size of the particles.
46 . A method, comprising:
introducing a first material to a selected portion of a medical device;
heating the first material or the selected portion, the first material and the selected portion fusing together.
47 . The method of claim 46 , wherein the first material is more radiopaque than a material of the medical device.
48 . The method of claim 46 , wherein the first material is capable of providing contrast during magnetic resonance imaging.
49 . The method of claim 46 , wherein the first material or the selected portion is heated with a laser.
50 . The method of claim 46 , wherein the first material is dispersed in a fluid.
51 . The method of claim 46 , wherein the heating is performed using magnetic induction.
52 . The method of claim 46 , wherein the selected portion comprises a polymer.
53 . The method of claim 46 , wherein the medical device is a stent, and the selected portion is a tab extending from a portion of the stent.
54 . The method of claim 46 , wherein the first material and the selected portion fuse together to form an alloy.
55 . The method of claim 46 , wherein the medical device is selected from the group consisting of a stent, a graft, a filter, a catheter, a guidewire, and an aneurysm coil.