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1. WO2007142736 - MANUFACTURING PROCESS FOR POLYMERIC STENTS

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[ EN ]

CLAIMS
WHAT IS CLAIMED IS:
1. A method of fabricating a stent delivery device comprising:
forming a polymeric tube using extrusion, the tube being drawn during extrusion so that a diameter of the formed tube is less than a target diameter;
radially deforming the formed tube so that the deformed tube comprises the target diameter;
forming a stent from the deformed tube, wherein forming the stent includes laser machining a stent pattern in the deformed tube with an ultra-short pulse laser; and
crimping the stent on a support element, wherein a temperature of the stent during crimping is above an ambient temperature.
2. The method of claim 1, wherein the stent pattern comprises
a plurality of cylindrical rings, each ring including a plurality of diamond-shaped cells having four curved elements defining the apices of the diamond-shaped cell, wherein a first and a second bar arm forming a longitudinally aligned curved element of the four curved elements and a third and a fourth bar arm form an opposing longitudinally aligned curved element of the four curved elements, wherein the first and the third bar arm form a circumferentially aligned curved element of the four curved elements and the second and the fourth bar arm form an opposing circumfemtially aligned curved element of the four curved elements; and
a plurality of linear bar arms parallel with a longitudinal axis of the stent connecting adjacent rings, wherein at least one linear bar arm connects an intersection of two circumferentially adjacent diamond-shaped cells with an intersection of two circumferentially adjacent diamond-shaped cells on an adjacent ring.

3. The method of claim 2, wherein a ratio of an outer circumference of the stent to the number of diamond-shaped cells around a circumference of the stent is 0.044
in/cell.
4. The method of claim 3, wherein a radius of curvature of the opposing
longitudinally aligned curved elements is between 0.004 in and 0.006 in.
5. The method of claim 3, wherein curved elements between circumferentially
adjacent cells have a radius of curvature of between 0.0025 in and 0.004 in.
6. The method of claim 3, wherein curved elements between linear bar arms and
adjacent bar arms of the diamond-shaped cells have a radius of curvature of
between 0.004 in and 0.006 in.
7. The method of claim 1, wherein the support element comprises a catheter and/or balloon.
8. The method of claim 1, wherein the target diameter is a diameter at which the stent pattern is formed by laser machining.
9. The method of claim 1, wherein the temperature of the stent during crimping is at or above a Tg of the polymer.
10. The method of claim 1, wherein the polymeric tube is formed during extrusion at a temperature at which a crystal nucleation rate is greater than a crystal growth rate of the polymer.
11. The method of claim 1 , further comprising axially deforming the formed tube, wherein the radially and axially deformed tube is at the target diameter.
12. The method of claim 1, wherein the target diameter is a diameter of a stent prior to crimping.
13. The method of claim 1, wherein the tube is radially deformed with an expansion ratio from 2 to 6.

14. The method of claim 1 , wherein the tube is formed during extrusion at a
temperature where a crystal nucleation rate is larger than a crystal growth rate of the polymer.
15. The method of claim 1, wherein the polymer is a semi-crystalline polymer.
16. A method of manufacturing a stent comprising:
forming a polymeric tube using extrusion, the tube being drawn during extrusion so that a diameter of the formed tube is less than a target diameter;
radially deforming the extruded tube to the target diameter; and
forming a stent from the deformed tube, wherein forming the stent includes laser machining a stent pattern in the deformed tube with an ultra-short pulse laser.
17. The method of claim 16, wherein the polymer is a semi-crystalline polymer.

18. A method of manufacturing a stent comprising:
radially deforming a polymeric tube about a cylindrical axis of the tube; and forming a stent from the deformed tube, wherein forming the stent includes laser machining a stent pattern in the deformed tube with an ultra-short pulse laser.
19. A method comprising:
radially deforming a polymeric tube about a cylindrical axis of the tube; and fabricating a stent from the deformed tube; and
crimping the stent on a support element, wherein a temperature of the stent during crimping is above an ambient temperature.
20. A method of manufacturing a stent comprising:
forming a stent from a polymeric tube, wherein forming the stent includes laser machining a stent pattern in the tube with an ultra-short pulse laser; and
crimping the stent on a catheter or a balloon, wherein a temperature of the stent during crimping is above an ambient temperature.