Multi-scale manufacturing technology development for 3D imaging catheters

这个NSERC-CRD项目的目标是开发设计和制造3D成像导管的制造技术。3D成像导管的制造涉及各种不同材料的部件，在微米尺度和毫米尺度。Colibri Technologies Inc.拥有3D成像导管设计和技术专利，其导管在导管市场上具有强大的潜力。使用3D成像使医生更容易识别心腔的解剖位置，并将导管引导到感兴趣的区域。对体内碘基染料进行x射线成像是目前用于引导和定位导管的标准技术，但它经常使外科医生不确定引导导管的方式。一种紧凑的导管可以产生3D图像，并允许医生积极指导手术，可以更快、更安全地进行手术，成功率更高。然而，下一代3D成像导管发展的关键挑战之一是具有成本效益的制造技术，用于生产3D微运动所需的微型部件和微尺度特征。为了加工这些导管组件，连接或焊接它们，并组装它们以生产3D成像导管，需要制定批量生产这些组件的工艺计划，开发用于陶瓷，金属和聚合物高质量切割的微铣削技术，激光加工小于一毫米的特征，飞秒激光制造透镜组件，连接或焊接两个组件，制造装配夹具。需要测量部件的尺寸和表面质量，表征导管的性能等。申请人之前曾与Colibri合作，以开发用于批量生产3D成像导管组件的微加工技术。已经取得了重大进展，并已加工出高质量的导管部件。然而，为了提高加工质量和生产效率，以及开发微型部件装配的创新制造工艺，还需要进一步的研究。

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.