A method of forming an implant includes providing a preformed shell formed from at least one cured elastomeric layer. The preformed shell includes an outer surface, an inner surface, and an opening for accessing an interior volume of the preformed shell. The method further includes expanding the preformed shell to an expanded state, in which the interior volume is greater than the interior volume of the preformed shell at a time of forming the preformed shell and forming an inner zone having at least one inner elastomeric layer on at least a portion of the inner surface of the preformed shell, while the shell is in the expanded state, thereby forming a multi-zone shell. The method further includes reducing the interior volume of the multi-zone shell, thereby contracting the at least one inner elastomeric layer of the inner zone and causing texturing of the at least one inner elastomeric layer.

Apparatus and methods are provided for creating tubular devices, e.g., as components for catheters, sheaths, and or other devices sized for introduction into a patient. In one embodiment, a method is provided for making a tubular device using a sheet of material including a coated first surface. The sheet is rolled around a mandrel until longitudinal edges of the sheet are disposed near or adjacent one another, e.g., without attaching the longitudinal edges together. A tubular braid is positioned over the sheet-wrapped mandrel, one or more tubular segments are positioned over the tubular braid, and heat shrink tubing is positioned over the tubular segments. The resulting assembly is heated to cause the tubular segments to at least partially reflow and/or otherwise laminate the tubular segments to the tubular braid and sheet. The heat shrink tubing and mandrel are then removed to create the tubular device.

Origami- and Kirigami-inspired assembly of predetermined three-dimensional forms is presented in comprehensive theoretical and experimental studies, with examples of a broad range of topologies and material compositions. The resulting engineering options in the construction of functional 3D structures have important implications for advanced microsystem technologies.

A method of making a waveguiding optical component includes processing a polymer optical material to form a billet having an axis of light transmission and having residual stress maintaining a transverse extent of the billet; placing the billet into a mold, the mold being configured to constrain transverse expansion of the billet according to a desired shape of the waveguiding optical component; and heating the billet in the mold to induce relaxation of the residual stress and corresponding transverse expansion of the billet, thereby forming the billet into the waveguiding optical component with the desired shape. An alternative method begins with a collection of individual canes or fiber segments which are fused during the heating process, bypassing a separate process of forming a billet.

Overmolded inserts and methods for forming the same The present disclosure is directed to overmolded inserts (100) with reduced internal residual stress and corresponding methods for forming the overmolded inserts. The overmolded inserts have a polymer housing; metal or metal allow tapered insert (104, 302) and a compression element (106, 304) disposed between the housing and the distal end of the tapered insert. During formation, the tapered insert and compression element are placed within a mold. The polymer housing material is heated and filled into the mold. As the polymer housing cools, the compression element is compressed between the polymer housing and the tapered insert. The overmolded inserts formed have reduced internal residual stress relative to a corresponding insert formed from non-tapered insert.

The invention provides a heat-shrinkable polyester film which has sufficient heat shrinkage properties in the main shrinkage direction that is the longitudinal direction without containing a monomer component that can form an amorphous component in a large amount, and which has a low heat shrinkage and a low shrinkage stress in the width direction orthogonal to the main shrinkage direction. The film has a heat shrinkage of 15-50% in a main shrinkage direction of the film and 0-12% in a direction orthogonal to the main shrinkage direction of the film, when treated for 10 seconds in hot water of 90 C., and a maximum shrinkage stress of 2-10 MPa in the main shrinkage direction of the film when measured under hot air of 90 C. The film contains 7-30 mol % of a constituent unit derived from diethylene glycol in 100 mol % of the whole polyester resin component.

Apparatus and methods are provided for creating tubular devices, e.g., as components for catheters, sheaths, and or other devices sized for introduction into a patient. In one embodiment, a method is provided for making a tubular device using a sheet of material including a coated first surface. The sheet is rolled around a mandrel until longitudinal edges of the sheet are disposed near or adjacent one another, e.g., without attaching the longitudinal edges together. A tubular braid is positioned over the sheet-wrapped mandrel, one or more tubular segments are positioned over the tubular braid, and heat shrink tubing is positioned over the tubular segments. The resulting assembly is heated to cause the tubular segments to at least partially reflow and/or otherwise laminate the tubular segments to the tubular braid and sheet. The heat shrink tubing and mandrel are then removed to create the tubular device.

A method of manufacturing a fluid impermeable rigid composite pipe (10) or hollow tube comprising the steps of:a. providing a supporting mandrel (15) that is shaped to define a bore of the pipe (10); b. laying onto the outer circumferential surface of the mandrel (10) one or more first tapes (11) made of a thermoplastic material thereby to create a first region (11) that is predominantly thermoplastic material adjacent the bore of the pipe (10); c. providing a plurality of tows (14) that comprise co-mingled reinforcing fibers and thermoplastic filaments; d. weaving a plurality of the tows (14) to form one or more circular braids (13) and laying down the one or more of the circular braids (13) on to the first layer (11): to form a second region (12); e. applying to the outer surface of the second region (12) a heat-shrinkable layer (13); f. heating the product of steps (b) to (e) on the mandrel (15) to a first temperature at which the thermoplastic materials of the one or more tapes 11 and the tows 14 melt and the heat-shrinkable layer 13 shrinks radially inwards to consolidate the melted thermoplastic material to form a thermoplastic matrix in which the reinforcing fibers are embedded and a fluid impermeable thermoplastic rich region (11) is formed at the bore of the pipe (10); and, g. allowing the pipe (10) to cool to form a self supporting pipe (10).

A method of forming an implant includes providing a preformed shell formed from at least one cured elastomeric layer. The preformed shell includes an outer surface, an inner surface, and an opening for accessing an interior volume of the preformed shell. The method further includes expanding the preformed shell to an expanded state, in which the interior volume is greater than the interior volume of the preformed shell at a time of forming the preformed shell and forming an inner zone having at least one inner elastomeric layer on at least a portion of the inner surface of the preformed shell, while the shell is in the expanded state, thereby forming a multi-zone shell. The method further includes reducing the interior volume of the multi-zone shell, thereby contracting the at least one inner elastomeric layer of the inner zone and causing texturing of the at least one inner elastomeric layer.

A method of forming a fluid-filled implant is provided. The method includes: forming a first zone of an elastomeric membrane defining at least one partially enclosed void space; expanding a volume of the void space, thereby expanding a volume enclosed by the first zone; forming a second zone comprising at least one elastomeric middle layer on at least a portion of the expanded first zone; and reducing the volume of the void space, thereby contracting elastomeric layers of the first zone and the second zone. The method also includes forming an adjustable implant from the elastomeric membrane by enclosing the void space to form at least one chamber.