Method of manufacturing a silicone medical balloon

1. A method of forming a balloon for a medical device, comprising:

extruding a cylindrical tube of silicone material;

partially curing the cylindrical tube by exposing the cylindrical tube to a first ultraviolet light source;

inflating the cylindrical tube within a mold to form the balloon; and

fully curing the balloon by exposing the balloon to a second ultraviolet light source.

2. The method of claim 1 , further comprising:

cutting a length of the cylindrical tube; and

inserting the length of the cylindrical tube into the mold.

3. The method of claim 1 , wherein the first ultraviolet light source has a wavelength which is greater than a wavelength of the second ultraviolet light source.

4. The method of claim 3 , wherein the wavelength of the second ultraviolet light source is at least 200 nm.

5. The method of claim 3 , wherein the wavelength of the first ultraviolet light source is no more than 520 nm.

6. The method of claim 1 , further comprising, coupling the balloon to a catheter by melting a first end and a second end of the balloon to an outer surface of a catheter.

7. The method of claim 6 , further comprising folding the balloon against the outer surface of the catheter.

8. The method of claim 1 , wherein partially curing the cylindrical tube comprises exposing the cylindrical tube to the first ultraviolet light source for no more than 60 seconds.

9. The method of claim 1 , wherein fully curing the cylindrical tube comprises exposing the cylindrical tube to the second ultraviolet light source for no more than 300 seconds.

10. A method of forming a balloon for a medical device, comprising

extruding liquid silicone rubber to form a hollow element;

partially curing the hollow element to form a semi-solid tube by exposing the liquid silicone rubber to a first ultraviolet light source;

inflating the semi-solid tube of the hollow element within a mold; and

fully curing the hollow element to form a balloon by exposing the semi-solid tube of the hollow element to a second ultraviolet light source.

11. The method of claim 10 , wherein extruding the liquid silicone rubber comprises extruding an outer surface of the hollow element with a laminar flow and extruding an inner surface of the hollow element with a laminar flow.

12. The method of claim 11 , wherein extruding the liquid silicone rubber comprises extruding an interior portion of the hollow element with a turbulent flow.

13. The method of claim 10 , wherein the first ultraviolet light source has an intensity which is less than an intensity of the second ultraviolet light source.

14. The method of claim 10 , wherein the liquid silicone rubber of the hollow element is exposed to the first ultraviolet light source for a shorter period of time than the semi-solid tube of the hollow element is exposed to the second ultraviolet light source.