Multi-scale manufacturing technology development for 3D imaging catheters

本NSERC-CRD项目的目的是开发用于设计和制造3D成像导管的制造技术。3D成像导管的制造涉及在微米尺度以及在毫米尺度的不同材料中的各种各样的组件。Colibri Technologies Inc.拥有3D成像导管设计和技术的专利，其导管在导管市场具有强大的潜力。3D成像的使用使医生更容易识别心腔中的解剖位置并将导管引导到感兴趣区域。体内碘基染料的X射线成像目前是用于导航和定位导管的标准技术，但它通常使外科医生不确定以何种方式导航导管。一个紧凑的导管，可以产生3D图像，并允许医生主动引导程序可以导致更快，更安全的程序，具有更高的成功率。然而，下一代3D成像导管开发的一个关键挑战领域是用于生产3D微运动所需的微型组件和微尺度特征的成本效益制造技术。为了加工这些导管部件，接合或焊接它们，并组装它们以生产3D成像导管，用于批量生产这些部件的工艺计划，用于陶瓷、金属和聚合物的高质量切割的微铣削技术开发，小于一毫米的特征的激光加工，透镜部件的飞秒激光制造，两个部件的接合或焊接，用于组装的夹具的制造，需要测量组件的尺寸和表面质量、表征导管性能等。申请人之前曾与Colibri合作开发用于批量生产3D成像导管组件的微加工技术。已经取得了重大进展，并且已经加工出高质量的导管组件。然而，需要进一步的研究，以提高加工质量和生产力的成本效益，以及开发创新的制造工艺组装的微型部件。

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.