Multi-scale manufacturing technology development for 3D imaging catheters

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The objective of this NSERC-CRD project is to develop manufacturing technologies for design and manufacturing of 3D imaging catheters. Manufacturing of 3D imaging catheters involves a wide variety of components in different materials at the micro-scale as well as at the millimeter-scale. Colibri Technologies Inc. has patented 3D imaging catheter designs and technologies, and their catheters have strong potential in the catheter market. Use of 3D imaging makes it easier for the physician to identify anatomical locations in a cardiac chamber and guide a catheter to a region of interest. X-ray imaging of the iodine based dye within the body is currently the standard technique used to navigate and position the catheter, but it often leaves the surgeon unsure which way to navigate the catheter. A compact catheter that can produce 3D images and allow the physician to actively guide procedures can lead to faster and safer procedures with a higher success rates. However, one of the key challenging areas of development for this next generation of 3D imaging catheters is the cost-effective fabrication technology for production of the miniature components and micro-scale features needed for 3D micro-motions. In order to machine these catheter components, join or weld them, and assemble them to produce a 3D imaging catheter, process plans for batch production of these components, micro-milling technology development for high quality cutting of ceramics, metals, and polymers, laser machining of features smaller than a millimeter, femtosecond laser fabrication of lens components, joining or welding of two components, fabrication of jigs for assembly, measurement of components' dimensional and surface quality, characterization of catheter performance, etc. are required. The applicant has collaborated with Colibri previously in order to develop micro-machining technologies for batch production of 3D imaging catheter components. A significant progress has been made and high quality catheter components have been machined. However, further research is required to enhance machining quality and productivity cost-effectively as well as to develop innovative manufacturing processes for assembly of miniature components.