Methods of making medical devices
First Claim
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1. A method of making a medical device having a covered scaffold, comprising the steps of:
- a) Forming a plurality of structural scaffold members with an interstitial area between the plurality of structural scaffold members in association with a deposition substrate;
b) Depositing a cover-forming material onto the formed scaffold, thereby monolithically joining the scaffold and the cover-forming material;
disposing a second scaffold member onto the cover-forming material;
depositing a sacrificial material onto the second scaffold member and the cover-forming material;
removing portions of the sacrificial material to expose portions of the second scaffold member;
depositing a second cover-forming material onto the exposed portions of the second scaffold member and the sacrificial material;
c) Creating a plurality of openings passing through the cover-forming material and over the interstitial area;
creating a plurality of openings in the second cover-forming material that do not overlie the second scaffold member;
andd) Releasing the monolithically joined scaffold and cover-forming material from the deposition substrate;
removing the sacrificial material to form a void plenum between the cover-forming material and the second-cover forming material; and
loading at least one pharmacologically agent into the void plenum between the cover-forming material and the second cover-forming material.
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Abstract
Scaffold-supported metal or pseudometallic film covers suitable for use as medical devices are disclosed together with methods of fabricating the devices. Methods for making the medical devices consist of either providing or forming a scaffold, then depositing a metallic or pseudometallic film cover onto the scaffold in such a manner as to form an integral, substantially monolithic junction between the deposited cover material and the scaffold.
255 Citations
19 Claims
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1. A method of making a medical device having a covered scaffold, comprising the steps of:
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a) Forming a plurality of structural scaffold members with an interstitial area between the plurality of structural scaffold members in association with a deposition substrate; b) Depositing a cover-forming material onto the formed scaffold, thereby monolithically joining the scaffold and the cover-forming material;
disposing a second scaffold member onto the cover-forming material;
depositing a sacrificial material onto the second scaffold member and the cover-forming material;
removing portions of the sacrificial material to expose portions of the second scaffold member;
depositing a second cover-forming material onto the exposed portions of the second scaffold member and the sacrificial material;c) Creating a plurality of openings passing through the cover-forming material and over the interstitial area;
creating a plurality of openings in the second cover-forming material that do not overlie the second scaffold member;and d) Releasing the monolithically joined scaffold and cover-forming material from the deposition substrate;
removing the sacrificial material to form a void plenum between the cover-forming material and the second-cover forming material; and
loading at least one pharmacologically agent into the void plenum between the cover-forming material and the second cover-forming material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method of making a medical device having a structural scaffold and a cover, comprising the steps of:
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a) Providing a substrate suitable for vacuum deposition of biocompatible metals and pseudometals thereupon, the substrate having a pattern imparted thereto corresponding to the structural scaffold including an interstitial area between the adjacent structural scaffolds; b) Vacuum depositing a scaffold-forming biocompatible metal or pseudometal onto the substrate and into the pattern; c) Planarizing the scaffold-forming biocompatible metal or pseudometal to a surface of the substrate such that at least a portion of the scaffold-forming biocompatible metal or pseudometal in the pattern is substantially co-planar with the surface of the substrate; d) Vacuum depositing a cover-forming biocompatible metal or pseudometal onto the substrate and the scaffold-forming biocompatible metal or pseudometal, vacuum depositing a second scaffold forming material on the cover-forming biocompatible metal or pseudometal, vacuum depositing a sacrificial material on the second scaffold forming material, and vacuum depositing a second cover-forming biocompatible metal or pseudometal on the second scaffold forming material, and removing the sacrificial material to form a void plenum between; e) Forming a plurality of openings in the deposited second cover-forming biocompatible metal or pseudometal which do not overlay the second structural scaffolds and loading at least one pharmacologically agent into the void plenum between the cover-forming material and the second cover-forming material; and f) Removing the substrate from the deposited scaffold-forming and cover-forming biocompatible metals or pseudometals. - View Dependent Claims (17, 18, 19)
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Specification