Cut tubular members for a medical device and methods for making and using the same

1. A medical device, comprising:

an elongate shaft having a proximal region and a distal region, wherein the shaft includes a core wire having a solid cross-section;

a tubular member disposed over the distal region of the shaft, the tubular member having an outer surface and an inner surface;

wherein the tubular member has a plurality of slots defined therein;

wherein a beveled slot is defined in the tubular member that has a first geometry at the outer surface and a second geometry at the inner surface, the first geometry being different from the second geometry;

wherein a bevel is formed in the tubular member that forms a transition between the first geometry and the second geometry of the beveled slot; and

wherein the bevel is an angled bevel that extends at a variable angle between the first geometry and the second geometry of the beveled slot.

2. The medical device of claim 1 , wherein the first geometry and the second geometry are geometrically similar shapes of different sizes.

3. The medical device of claim 1 , wherein the first geometry includes a shape selected from the group consisting of oval, elliptical, semi-circle, semi-oval, half-moon, and diamond.

4. The medical device of claim 1 , wherein the slots are sequentially disposed in longitudinal rows along the outer surface.

5. The medical device of claim 4 , wherein at least some of the slots are reversed relative to an immediately previous slot.

6. The medical device of claim 1 , wherein the tubular member includes a first pair of beams.

7. The medical device of claim 6 , wherein the tubular member includes a tube centerline and wherein the first pair of beams are offset a distance from the tube centerline.

8. A medical device, comprising:

an elongate shaft having a proximal region and a distal region, the shaft having a solid cross-section;

a nickel-titanium alloy tubular member disposed over the distal region of the shaft, the tubular member having an outer surface and an inner surface;

wherein the tubular member has a plurality of slots defined therein, the plurality of slots including a beveled slot that has a first geometry at the outer surface and a second geometry at the inner surface; and

wherein the tubular member includes a variable-angle bevel that extends between the outer surface and the inner surface adjacent the beveled slot at a variable angle such that the variable angle bevel follows a curved path between a first point along the outer surface and a second point along the inner surface and positioned radially inward from the first point.

9. The medical device of claim 8 , wherein the first geometry and the second geometry are geometrically similar shapes of different sizes.

10. The medical device of claim 8 , wherein the first geometry includes a shape selected from the group consisting of oval, elliptical, semi-circle, semi-oval, half-moon, and diamond.

11. The medical device of claim 8 , wherein the slots are sequentially disposed in longitudinal rows along the outer surface.

12. The medical device of claim 11 , wherein at least some of the slots are reversed relative to an immediately previous slot.

13. A medical device, comprising:

a nickel-titanium alloy tubular member having an outer surface and an inner surface;

wherein the nickel-titanium alloy tubular member has a plurality of slots defined therein, the slots including a beveled slot having a first geometry at the outer surface and a second geometry at the inner surface; and

wherein the nickel-titanium alloy tubular member includes a bevel between the outer surface and the inner surface adjacent the slots, the bevel extending between the outer surface and the inner surface such that between a first point along the outer surface of the tubular member and a second point along the inner surface of the tubular member and positioned directly radially inward from the first point, the bevel follows a curved path at a changing angle.

14. A method for manufacturing a guidewire, the method comprising the steps of:

providing a core wire having a solid cross-section;

providing a tubular member, the tubular member having an outer surface and an inner surface;

disposing the tubular member over the distal portion of the core wire;

providing a cutting blade having a curved cutting surface;

cutting a plurality of slots including a beveled slot into the tubular member with the cutting blade;

wherein the beveled slot has a first geometry at the outer surface and a second geometry at the inner surface, the first geometry being different from the second geometry;

wherein a bevel is formed in the tubular member that forms a transition between the first geometry and the second geometry of the beveled slot; and

wherein the bevel is a curved bevel that extends at a variable angle between the first geometry and the second geometry of the beveled slot such that between a first point along the outer surface of the tubular member and a second point along the inner surface of the tubular member and positioned directly radially inward from the first point, the curved bevel follows a curved path.