Methods of making an endovascular prosthesis using a deformable matrix

1. A method of making an endovascular prosthesis having a desired shape comprising:

applying a first layer of polymer onto a portion of a deformable forming member;

contacting a stent with the polymer to deform the forming member;

applying a second layer of polymer over at least a portion of the stent and first layer;

solidifying the layers of polymer to form the endovascular prosthesis;

removing the forming member; and

wherein the deformable forming member exhibits plasticity during application of the polymer layers and stent.

2. The method of claim 1 further comprising pressing the stent into the deformable forming member.

3. The method of claim 1 , wherein the deformable forming member comprises wax, polymer, elastomer, or shape memory alloy.

4. The method of claim 1 , wherein the deformable forming member comprises a non-deformable core and a deformable surface.

5. The method of claim 1 wherein the deformable forming member is melted, dissolved, contracted, expanded, evaporated, or distended.

6. The method of claim 1 , further comprising physically manipulating the endovascular prosthesis and deformable forming member to the desired shape before removing the deformable forming member.

7. The method of claim 1 , further comprising pressing the stent toward the deformable forming member, physically manipulating the endovascular prosthesis and deformable forming member to the desired shape, and removing the deformable forming member.

8. The method of claim 1 , wherein the first and second layers are solidified by cooling, curing, or chemical reaction.

9. A method of making an endovascular prosthesis having a desired shape comprising:

applying a first layer of polymer to a portion of a deformable forming member;

applying a graft material over at least a portion of the first layer and deformable forming member;

contacting a stent with the graft material, to deform the forming member;

applying a second layer of polymer over at least a portion of the stent and graft material;

solidifying the layers of polymer to thereby form the endovascular prosthesis;

removing the forming member; and

wherein the deformable forming member exhibits plasticity during application of the polymer layers and stent.

10. The method of claim 9 further comprising pressing the stent toward the deformable forming member.

11. The method of claim 9 , wherein the deformable forming member comprises wax, polymer, elastomer, or shape memory alloy.

12. The method of claim 9 , wherein the deformable forming member comprises a non-deformable core and a deformable surface layer.

13. The method of claim 9 , wherein the deformable forming member is removed by undergoing a change.

14. The method of claim 13 wherein the deformable forming member is melted, dissolved, contracted, expanded, evaporated, or distended.

15. The method of claim 9 , further comprising physically manipulating the stent and deformable forming member to the desired shape before removing the deformable forming member.

16. The method of claim 9 , further comprising pressing the stent toward the deformable forming member, physically manipulating the endovascular prosthesis and deformable forming member to the desired shape, and removing the deformable forming member.

17. The method of claim 9 , wherein the first and second layers are solidified by cooling, curing, or chemical reaction.