Image Guided Surgery System Guide Wire and Methods of Manufacturing and Use

1 . A method of manufacturing a guide wire system, the method comprising:

positioning a first connector at a proximal end of a guide wire;

positioning a second connector on the guide wire between a distal end of the guide wire and the proximal end of the guide wire;

positioning an electromagnetic sensor at the distal end of the guide wire; and

positioning a polymeric tube around at least a portion of the guide wire and at least a portion of the electromagnetic sensor.

2 . The method of claim 1 , further comprising:

applying a heat source to at least a portion of the polymeric tube.

3 . The method of claim 2 , wherein applying the heat source to at least a portion of the polymeric tube comprises:

applying the heat source adjacent the proximal end of the guide wire to secure the first connector to the proximal end of the guide wire.

4 . The method of claim 2 , wherein applying the heat source to at least a portion of the polymeric tube comprises:

applying the heat source adjacent the distal end of the guide wire to secure the electromagnetic sensor to the distal end of the guide wire.

5 . The method of claim 1 , further comprising:

potting the electromagnetic sensor in an epoxy.

6 . The method of claim 1 , positioning the electromagnetic sensor at the distal end of the guide wire comprises:

securing the electromagnetic sensor to the distal end of the guide wire via a radio frequency tipping die.

7 . The method of claim 1 , further comprising:

positioning a camera at the distal end of the guide wire.

8 . The method of claim 1 , further comprising:

applying a lubricious coating to the guide wire.

9 . A method of treating a sinus cavity of a subject, the method comprising:

(a) inserting a distal portion of a guide wire system into a lumen of a balloon dilation catheter, wherein the guide wire system includes:

(i) a guide wire having a distal end and a proximal end,

(ii) a first connector positioned at and coupled to the proximal end of the guide wire, and

(iii) a second connector coupled to the guide wire between the distal end and the proximal end;

(b) coupling the second connector of the guide wire system to the balloon dilation catheter such the distal end of the guide wire is fixed with respect to a distal end of the balloon dilation catheter;

(c) directing the distal end of the guide wire and the distal end of the balloon dilation catheter to the sinus cavity; and

(d) inflating a balloon.

10 . The method of claim 9 , wherein the guide wire system further comprises:

an electromagnetic sensor coupled to the distal end of the guide wire.

11 . The method of claim 10 , wherein directing the distal end of the guide wire and the distal end of the balloon dilation catheter to the sinus cavity comprises:

directing the distal end of the guide wire and the distal end of the balloon dilation catheter simultaneously to a drainage pathway of the sinus cavity using data received from the electromagnetic sensor.

12 . The method of claim 11 , wherein the drainage pathway of the sinus cavity comprises a frontal recess of a frontal sinus cavity.

13 . The method of claim 10 , wherein the guide wire system further comprises:

a polymeric tube surrounding at least a portion of the guide wire and at least a portion of the electromagnetic sensor.

14 . The method of claim 9 , wherein the balloon dilation catheter includes:

an inner guide member including the lumen.

15 . The method of claim 14 , wherein the balloon dilation catheter further includes a movable shaft coupled to the balloon and mounted on the inner guide member, and wherein the method further comprises:

allowing the movable shaft to move along the inner guide member, while preventing the movable shaft from rotating around the inner guide member.

16 . The method of claim 9 , further comprising:

re-positioning the distal end of the balloon dilation catheter based at least in part on a determined location of the distal end of the guide wire with respect to the sinus cavity.

17 . The method of claim 16 , further comprising:

prior to re-positioning the distal end of the balloon dilation catheter, deflating the balloon; and

re-inflating the balloon once the distal end of the balloon dilation catheter is re-positioned.

18 . The method of claim 9 , wherein the first connector comprises a pin connector, and wherein the second connector comprises a bayonet connector, and wherein the method further comprises:

coupling the guide wire system to the balloon dilation catheter via coupling the bayonet connector of the second connector to a complementary bayonet connector of the balloon dilation catheter.