High-strength multi-component suture

1. A method for making an expanded polytetrafluoroethylene (PTFE) monofilament, the method comprising:

forming a first paste by mixing a PTFE powder with a hydrocarbon solvent, the first paste including less than about 16% of the hydrocarbon solvent by weight;

curing the first paste by exposing the first paste to a first temperature for a first time duration;

forming an extrusion preform by pressing the first paste into a form;

forming a green monofilament by extruding the first paste through a die;

expanding the green monofilament by exposing the green monofilament to a second temperature for a second time duration, the second time duration occurring after the first time duration;

stretching the green monofilament substantially along a longitudinal axis of the green monofilament, the stretching the green monofilament occurring after the expanding the green monofilament; and

sintering the green monofilament after the stretching the green monofilament,

wherein the expanding, stretching, and sintering are done in a continuous process.

2. The method of claim 1 , wherein the forming the first paste includes maintaining a mixture of the PTFE powder and the hydrocarbon solvent at a substantially constant temperature.

3. The method of claim 2 , wherein the substantially constant temperature is between about 50 degrees Fahrenheit and about 60 degrees Fahrenheit.

4. The method of claim 1 , wherein the first temperature is between about 68 degrees Fahrenheit to about 78 degrees Fahrenheit.

5. The method of claim 4 , wherein the first time duration is greater than about 24 hours.

6. The method of claim 1 , wherein the extrusion preform is substantially free from mechanical forces acting on a free surface of the extrusion preform during the first time duration.

7. The method of claim 1 , wherein the forming the extrusion preform includes imparting a pressure on the first paste between about 150 psi to about 190 psi.

8. The method of claim 1 , wherein the forming the extrusion preform includes:

forming a second paste,

disposing a divider in the form,

disposing the second paste in the form such that the second paste is in contact with a first side of the divider, the first side of the divider being opposite a second side of the divider that is in contact with the first paste.

9. The method of claim 8 , wherein a color of the first paste is different from a color of the second paste.

10. The method of claim 1 , wherein the second temperature ranges from about 520 degrees Fahrenheit to about 800 degrees Fahrenheit.

11. The method of claim 1 , wherein expanding the green monofilament includes exposing the green monofilament to an environment at the second temperature.

12. The method of claim 1 , wherein the second time duration is between about 0.1 and about 0.5 seconds.

13. The method of claim 1 , wherein the sintering the green monofilament includes exposing the green monofilament to a temperature greater than about 700° F. for a third time duration.

14. The method of claim 1 , wherein the forming the green monofilament includes imparting a pressure on the first paste between about 200 psi and about 400 psi.

15. The method of claim 8 , wherein the forming the green monofilament includes rotating an end of the green monofilament about a longitudinal axis of the green monofilament.