WO2008094504A1

WO2008094504A1 - Medical prosthesis and method of production

Info

Publication number: WO2008094504A1
Application number: PCT/US2008/001089
Authority: WO
Inventors: Aaron P. Barr; Michael P. Debruyne; Jay A. Dittman; Michael C. Hoffa; Jason A. Mead; Benjamin Nickless
Original assignee: Cook Incorporated
Priority date: 2007-01-29
Filing date: 2008-01-28
Publication date: 2008-08-07
Also published as: AU2008211193A1; US20080178459A1; JP2010516393A; US8024851B2; EP2107895A1

Abstract

The invention relates to a method for producing a radially expandable prosthesis by laser cutting a pattern in a tubular member, which member has an outer diameter at least as great as the expanded diameter of the prosthesis. The prosthesis may be a Z-stent which can be cut out to have integral barbs or notches along its struts. The apexes between the struts may be relatively thin.

Description

MEDICAL PROSTHESIS AND METHOD OF PRODUCTION

Description Technical Field

The present invention relates generally to medical devices and, in particular, to a method of producing a radially expandable prosthesis. Background of the Invention

Intraluminal prostheses, such as stents, are generally known. Intraluminal stents may be deployed at a narrowed site in a body lumen, for example a blood vessel, to strengthen, support or repair the lumen. With angioplasty for example, implantations of stents have substantially advanced the treatment of occluded blood vessels. Once implanted, the prosthesis strengthens that part of the vessel such that blood flow is ensured.

Preferably, intraluminal stents have a small cross-sectional diameter and/or profile for introducing the stent into the affected body lumen. A configuration which is extremely suited for implantation in a body lumen is a generally cylindrical prosthesis which can radially expand from a first, small, collapsed diameter to a second, larger, expanded diameter. Such prostheses can be implanted in a body lumen by placing them on a catheter and transporting them through the lumen to the desired location. The prosthesis may be self-expanding or the catheter may be provided with a balloon or another expansion mechanism which exerts a radial outwards pressure on the prosthesis so that the prosthesis expands to a larger diameter.

One method of producing expandable intraluminal prostheses is by cutting a metal cannula around its circumference, for example to form a stent. Typically, the metal cannula is the size of the stent in its collapsed delivery state. Alternatively, the cannula is an intermediate size, between that of the collapsed diameter and expanded diameter of the stent.

Stents formed from an intermediate or collapsed size cannula may undesirably twist during expansion due to the stent's thin bars or struts. Another concern of intermediate or compressed-diameter cannula-formed stents is non-uniform radial expansion of the stent. Thin, flexible strut segments may not deform outwardly in the same manner and to the same degree as strut segments of higher radial strength, possibly resulting in stent segments extending or "hanging" into the lumen. Particularly in vascular stents, local blood flow turbulence can occur at these points that might contribute to thrombus formation. A design that increases longitudinal and radial strength and stability, and evenly distributes bending stresses is less prone to twisting and non-uniform expansion.

Still another consideration is stent migration following implantation due to physiological forces within the body lumen. Pulsatile flow is a major force that stents encounter; thus stents and endoluminal prostheses, if not properly anchored, may move downstream in the blood lumen in which they are placed. If the stents or endoluminal prostheses do migrate, their effectiveness may be diminished. To address migration, manufacturers may solder or otherwise bond outwardly-extending barbs or hooks to the prosthesis. However, non-integral barbs may deform from repeated physiological stresses, particularly the cyclical loading caused by cardiovascular pulsatile forces. Summary of the Invention

Aspects of the present invention seek to overcome or reduce one or more of the above problems.

According to a first aspect of the present invention, there is provided a method of producing a radially expandable prosthesis, comprising: providing a tubular member having an outer diameter; cutting a pattern in the tubular member to provide a tubular prosthesis where the tubular prosthesis is adapted to have a compressed diameter for endoluminal delivery and an expanded diameter for use upon implantation; where the tubular member outer diameter is at least as great as the prosthesis expanded diameter.

An advantage of a prosthesis produced by the above method is the avoidance of or reduction in twisting as it is deployed. In addition, it possesses high radial strength to enable the body lumen to be maintained substantially completely open.

The tubular member outer diameter is preferably substantially equal to the prosthesis expanded diameter.

In other embodiments the tubular member outer diameter may be larger than the prosthesis expanded diameter. This provides an increased resistance to twisting and a yet higher radial strength. The tubular member may have a circular, elliptical or other curved cross- section.

According to a second aspect of the present invention, there is provided a method of producing a radially expandable stent, comprising: providing a tubular member having an outer diameter; laser cutting a zigzag pattern to provide a zigzag stent comprising apexes and struts; where the zigzag stent is adapted to have a compressed diameter for endoluminal delivery and an expanded diameter for use upon implantation; where the apexes have a width less than the struts; where the struts comprise integral barbs; where the tubular member outer diameter is at least as great as the expanded diameter of the stent.

According to a third aspect of the present invention, there is provided a method of producing a stent comprising: providing a tubular member, and cutting a zigzag pattern comprising apexes and struts to produce a zigzag stent, wherein said apexes have a width less than said struts. The cutting step is preferably performed by a laser.

According to a fourth aspect of the present invention there is provided a zigzag stent comprising struts interconnected by apexes, wherein said apexes have a width less than said struts.

By laser cutting a Z type stent, the area of the bends or apexes can be a much smaller area. The result is that the collapsed stent can be of much smaller diameter at the ends. Conventional wire formed stents essentially all have a hairpin type bend at each apex. A hairpin bend or fold occupies more space than a cut out pattern. By reducing the bulk at the bends in a collapsed stent or stent graft, a smaller delivery system can be used. In a typical delivery system, the delivery sheath outside diameter can be reduced by as much as about 10%.

According to a fifth aspect of the present invention, there is provided a method of producing a prosthesis comprising: providing a tubular member of a first material; coating the tubular member with at least one second material; and cutting a pattern in said coated tubular member to provide a tubular prosthesis.

A prosthesis produced by this method has the advantage of two or materials in one device. The advantages could include structural advantages, for example the strength provided by composite materials. A first material or a polymer material, such as steel, can be coated with carbon, Kevlar or glass fibres. Where the prosthesis is a Z-stent member, the fibres may wound on the tubular member at the same helix angle as the struts of the Z-stent. In this way, half of the fibres are parallel to each strut for maximum strength.

A composite stent member is lighter than a stent member solely of metal, thus reducing the tendency for the stent member to migrate and also rendering it MRI compatible.

The advantages of the method may also be functional. For example a base prosthesis of stainless steel or Nitinol can be coated with a layer of silver on the surface as a bioactive layer.

According to a sixth aspect of the present invention, there is provided a Z-stent member comprising a first layer covered by a second layer comprising fibres, the Z- stent member having a zigzag configuration comprising apexes and struts, wherein the fibres are laid or wound substantially parallel to half of the struts. An advantage of such a stent member is that half the struts have fibres parallel to them to give maximum strength. The first layer may be of steel Nitinol or a polymer material, and the second layer may comprise carbon, Kevlar or glass fibres.

According to a seventh aspect of the present invention there is provided a method of producing a stent member comprising: providing a tubular member; and cutting a pattern in said tubular member to produce a stent member, wherein barbs are incorporated in said pattern.

Cutting the stent so that the barbs are incorporated in the pattern is an advantage because this eliminates the need to attach a separate barb. Separate, attached barbs occupy more space (the attach point has bulk and dimension). Soldering, brazing or welding can promote corrosion. With the present arrangement, complex barb patterns such as secondary barbs at the point to prevent the primary barb from pulling out of or retracting from the tissue can easily be made.

According to an eighth aspect of the present invention, there is provided a method of producing a stent member comprising: providing a tubular member; and cutting a pattern in said tubular member to produce a stent member, wherein notches along the stent member are incorporated in said pattern.

By cutting the stent member with notches to allow for a sutures, the stent can be held more securely relative to its position on graft material. This reduces stent to graft wear as the stent moves relative to the graft over extended periods of time. Any movement between the stent and graft material would eventually wear through the graft material resulting in a small hole and the potential for a leak into the aneurysm. In addition, since the area of the stent member is reduced in the area where the suture wraps around the stent strut, the overall size of the suture wrap is reduced, resulting in a smaller collapsed size, allowing a smaller introducer system. The notches can be replaced or supplemented by holes through the struts and arranged to similarly receive sutures. Again, the cutting is preferably effected by a laser. Brief Description of the Drawing

FIG. 1 A is a perspective drawing of a tubular member with a zigzag-shaped prosthesis pattern.

FIG. 1B is a perspective drawing of a zigzag-shaped prosthesis that has been cut from the tubular member of FIG. 1A.

FIG. 2 is a perspective drawing of a tubular member with a zigzag-shaped prosthesis pattern having reduced-width apexes.

FIG. 3 is a perspective drawing of a tubular member with a zigzag-shaped prosthesis pattern comprising integral barbs.

FIG. 4A is a perspective drawing of a tubular member with a zigzag-shaped prosthesis pattern comprising notches.

FIG. 4B is a perspective drawing of a zigzag-shaped prosthesis cut from the tubular member of FIG. 4A that is sutured to graft material.

FIG. 5 is a perspective drawing of a prosthesis comprising cavities.

FIG. 6 is a cross-sectional view of a prosthesis coated with therapeutic agent. FIG. 7 is a cross-sectional view of a prosthesis coated with therapeutic agent. Detailed Description

The present invention provides methods for producing an expandable prosthesis. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or eguivalent to those described herein can be used in the practice or testing of the present invention. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

The term "implantable" refers to an ability of a medical device to be positioned at a location within a body, such as within a body lumen.

The term "cavity" as used herein refers to any well, hole, depression, slot, groove, or the like included in the medical device in any manner.

As used herein, the term "body vessel" means any tube-shaped body passage lumen that conducts fluid, including but not limited to blood vessels such as those of the human vasculature system, esophageal, intestinal, billiary, urethral and ureteral passages.

The term "biocompatible" refers to a material that is substantially non-toxic in the in vivo environment of its intended use, and that is not substantially rejected by the patient's physiological system (i.e., is non-antigenic). This can be gauged by the ability of a material to pass the biocompatibility tests set forth in International Standards Organization (ISO) Standard No. 10993 and/or the U.S. Pharmacopeia (USP) 23 and/or the U.S. Food and Drug Administration (FDA) blue book memorandum No. G95-1 , entitled "Use of International Standard ISO-10993, Biological Evaluation of Medical Devices Part-1 : Evaluation and Testing." Typically, these tests measure a material's toxicity, infectivity, pyrogenicity, irritation potential, reactivity, hemolytic activity, carcinogenicity and/or immunogenicity. A biocompatible structure or material, when introduced into a majority of patients, will not cause a significantly adverse, long-lived or escalating biological reaction or response, and is distinguished from a mild, transient inflammation which typically accompanies surgery or implantation of foreign objects into a living organism.

The term "endoluminal" describes objects that are found or can be placed inside a lumen or space in the human or animal body. This includes lumens such as blood vessels, parts of the gastrointestinal tract, ducts such as bile ducts, parts of the respiratory system, etc. "Endoluminal prosthesis" thus describes a prosthesis that can be placed inside one of these lumens.

The term "about" used with reference to a quantity includes variations in the recited quantity that are equivalent to the quantity recited, such as an amount that is insubstantially different from a recited quantity for an intended purpose or function.

Prosthesis

The present invention is applicable to methods of producing implantable or insertable prostheses of any shape or configuration from a large diameter tubular member. Typical subjects (also referred to herein as "patients") are vertebrate subjects (i.e., members of the subphylum cordata), including, mammals such as cattle, sheep, pigs, goats, horses, dogs, cats and humans.

Typical sites for placement of the prosthesis include the coronary and peripheral vasculature (collectively referred to herein as the vasculature), heart, esophagus, trachea, colon, gastrointestinal tract, biliary tract, urinary tract, bladder, prostate, brain and surgical sites. The prosthesis may be any medical device that is introduced temporarily or permanently into the body for the prophylaxis or therapy of a medical condition. For example, such prostheses may include, but are not limited to, stents, stent grafts, catheters, guidewires, balloons, filters (e.g., vena cava filters), cerebral aneurysm filler coils, intraluminal paving systems, valves (e.g., venous valves), abdominal aortic aneurysm (AAA) grafts, embolic coils, bone substitutes, intraluminal devices, vascular supports, or other known biocompatible devices. Preferably, the prosthesis is a stent.

Intraluminal stents for use in connection with the present invention may comprise a patterned tubular member. Examples include endovascular, biliary, tracheal, gastrointestinal, urethral, esophageal and coronary vascular stents. The intraluminal stents may be, for example, balloon-expandable or self-expandable. Thus, although certain examples will be described herein with reference to vascular stents, the present invention is applicable to other prostheses, including other types of stents.

It should be understond that the materials used to comprise the prostheses need only be biocompatible or able to be made biocompatible. Examples of suitable materials include, without limitation, stainless steel, nitinol, MP35N, gold, tantalum, platinum or platinum irdium, niobium, tungsten, iconel, ceramic, nickel, titanium, stainless steel/titanium composite, cobalt, chromium, cobalt/chromium alloys, magnesium, aluminum, or other biocompatible metals and/or composites or alloys such as carbon or carbon fiber, cellulose acetate, cellulose nitrate, silicone, cross- linked polyvinyl alcohol (PVA) hydrogel, cross-linked PVA hydrogel foam, polyurethane, polyamide, styrene isobutylene-styrene block copolymer (Kraton), polyethylene teraphthalate, polyurethane, polyamide, polyester, polyorthoester, polyanhydride, polyether sulfone, polycarbonate, polypropylene, high molecular weight polyethylene, polytetrafluoroethylene, or other biocompatible polymeric material, or mixture of copolymers thereof; polyesters such as, polylactic acid, polyglycolic acid or copolymers thereof, a polyanhydride, polycaprolactone, polyhydroxybutyrate valerate or other biodegradable polymer, or mixtures or copolymers thereof; extracellular matrix components, proteins, collagen, fibrin, or combinations thereof. Preferably, the prosthesis comprises stainless steel or nitinol. Methods of Producing Prostheses

In one example, the method comprises providing a tubular member and cutting the tubular member to form a prosthesis. The prosthesis may be balloon-expandable or, preferably, self-expanding and is preferably a stent, for example a bifurcated stent, a stent configured for any blood vessel including coronary arteries and peripheral arteries (e.g., renal, superficial femoral, carotid, and the like), a urethral stent, a biliary stent, a tracheal stent, a gastrointestinal stent, or an esophageal stent. The diameter of the tubular member is at least as large as the expanded diameter of the prosthesis. While a round tubular member and stent are depicted in the examples shown herein, other tubular member shapes, e.g., square, triangular, D-shaped, polygonal, etc., may be used from which a prosthesis may be cut.

The tubular member may be cut in any way known to one of skill in the art. Preferably, the tubular member is cut using lasers, but may be cut, for example, by sawing, power hacksawing, shearing, abrasive cutting, plasma, or thermal cutting. The prosthesis may have any configuration possible, including but not limited to a sinusoidal shape, a zigzag shape, a mesh of interconnecting struts, or any other suitable configuration. Preferably, the prosthesis has a zigzag shape.

For example, FIG. 1A shows a tubular member 100 from which a prosthesis may be produced. The prosthesis profile 110 shows a pattern with which a prosthesis may be cut. The diameter 102 of the tubular member 100 preferably relates to the desired dimensions of the prosthesis in an expanded state. The wall thickness 104 of the tubular member 100 should approximate the desired thickness of the final prosthesis. The length 106 of the tubular member 100 should accommodate the desired length of the final prosthesis. FIG. 1B illustrates the prosthesis of FIG. 1A after the prosthesis 150 has been cut from the tubular member 100.

In another example, the apexes of a zigzag-shaped prosthesis, for example a stent, may be cut to be thinner than the struts of the prosthesis. For example, FIG. 2 illustrates a tubular member 200 from which a stent may be produced. The stent profile 210 shows a pattern with which a stent comprising reduced diameter apexes 212 may be produced. The result of reduced diameter apexes 212 is that the collapsed configuration of the stent may be much smaller at the ends. By reducing the bulk at the apexes in a collapsed stent, a smaller delivery system may be used, e.g. up to 10% smaller. Structural Features

A prosthesis according to the present invention may optionally include supplemental attachment means, such as anchoring devices, searing, bonding, gluing, or otherwise adhering the prosthesis to the vessel wall or combinations thereof. For example, the prosthesis may be secured in place with one or more anchoring devices.

The art provides a wide variety of structural features that are acceptable for use as medical device anchoring devices, and any suitable structural feature can be used. For example, individual barbs may be used to maintain a prosthesis implanted in a body vessel. Anchoring devices may be secured to the prosthesis by any means known to one skilled in the art, including but not limited to welding, stitching, bonding, and adhesives. Preferably, anchoring devices are an integral part of the prosthesis.

For example, in one embodiment a prosthesis may comprise features, such as integral barbs, that maintain the prosthesis in position following implantation in a body vessel. For example, FIG. 3 illustrates a prosthesis comprising integral barbs to facilitate maintenance in a body vessel. FIG. 3 depicts a tubular member 300 with line or barb profile 310 from which a prosthesis with integral barbs may be cut.

In some embodiments the number, arrangement, and configuration of integral barbs can vary according to design preference and the clinical use of the prosthesis. For example, the barb profile 310 can be varied. In particular, the distance 314 between barbs 312 and the height 316 and shape of the barbs can be varied. The barbs can have any suitable shape, including points or "fish hook"-like configurations. The opposing side 311 of the prosthesis may also be cut to provide additional barbs. The desired barb profile can be determined by the level of traction that the particular application requires and/or concerns about the damage to the surrounding body vessel that may be caused by the barbs, inter alia.

In other embodiments, the prosthesis may include an area of reduced diameter to aid in operatively connecting a graft material to the device. For example, FIGS. 4A and 4B illustrate a stent with notches 412 to aid in suturing the stent to a graft material. FIG. 4A depicts a tubular member 400 from which a stent may be produced. The line or notch profile 410 shows a pattern with which a stent comprising notches 412 may be cut. Notches 412 are of a reduced width permitting the size of the suture wrap 420 to reduce and permit for a smaller compressed delivery configuration of the stent-graft 450. Additionally, notches 412 permit the medical device to be connected more securely relative to its position on the graft material. This reduces stent 430 to graft 440 wear as the stent 430 moves relative to the graft 440 over extended periods of time. Alternatively, suture bulk may be reduced with a prosthesis that includes cavities allowing for a continuous suture. Radiopaque Material

Also provided are embodiments wherein the prosthesis comprises a means for orienting the prosthesis within a body lumen. For example, a prosthesis may comprise a marker, such as a radiopaque portion of the prosthesis that would be seen by remote imaging methods including X-ray, ultrasound, Magnetic Resonance Imaging and the like, or by detecting a signal from or corresponding to the marker.

For example, in some embodiments, a prosthesis may comprise cavities for receiving a radiopaque material (see, e.g., co-pending U.S. application Serial No. 10/870,079, incorporated herein by reference). FIG. 5 depicts one example of prosthesis 500 comprising cavities 510 loaded with radiopaque material for orienting the prosthesis 500 within a body lumen. The radiopaque material may be located on the prosthesis in any possible configuration. Preferably, radiopaque material is strategically located on the prosthesis to provide cues for rotational and longitudinal orientation within a body vessel. The degree of radiopacity contrast can be altered by implant content.

In other embodiments, the delivery device can comprise a frame with radiopaque indicia relating to the orientation of the prosthesis within the body vessel. In other examples, indicia can be located, for example, on a portion of a delivery catheter that can be correlated to the location of the prosthesis within a body vessel.

The prosthesis or delivery device may comprise one or more radiopaque materials to facilitate tracking and positioning of the medical device, which may be added in any fabrication method or absorbed into or sprayed onto the surface of part or all of the prosthesis. Common radiopaque materials include barium sulfate, bismuth subcarbonate, and zirconium dioxide. Other radiopaque elements include: cadmium, tungsten, gold, tantalum, bismuth, platium, iridium, and rhodium. Radiopacity is typically determined by fluoroscope or x-ray film. Therapeutic Agents

An implantable prosthesis may optionally comprise a bioactive agent. For example, a prosthesis may comprise cavities, similar to those of FIG. 5, that may be loaded with therapeutic agent. Alternatively, prostheses may be coated with therapeutic agent.

For example, in one embodiment, a layer of therapeutic agent may be deposited on at least a portion of the surface of a prosthesis, or on a primer layer which is placed directly on the surface of a prosthesis. FIG. 6 shows a cross-sectional view of the surface of a coated prosthesis comprising a first layer of therapeutic agent 600 deposited on a prosthesis 610.

The present invention also contemplates prostheses having various multiple layer coating configurations. The coating configuration may contain multiple therapeutic agents (hydrophilic and/or hydrophobic), non-polymers (such as a vitamin), a porous biostable polymer, a bioabsorbable polymer, or any combination thereof. For example, FIG. 7 shows a cross-sectional view of the surface of a second coated prosthesis 700 comprising a first layer of therapeutic agent 710 and a second layer of a bioabsorbable polymer 720, such as polylactic acid, to control the rate of therapeutic agent elution. The coating layer(s) may be deposited on the prosthesis in any suitable manner. For example, the coating may be deposited onto the prosthesis by spraying, dipping, pouring, pumping, brushing, wiping, ultrasonic deposition, vacuum deposition, vapor deposition, plasma deposition, electrostatic deposition, epitaxial growth, or any other method known to those skilled in the art. Prostheses may be coated before or after cutting from a tubular member.

Therapeutic agents that may be used in the present invention include, but are not limited to, pharmaceutically acceptable compositions containing any of the therapeutic agents or classes of therapeutic agents listed herein, as well as any salts and/or pharmaceutically acceptable formulations thereof. Table 1 below provides a non-exclusive list of classes of therapeutic agents and some corresponding exemplary active ingredients.

Table 1

Other desirable therapeutic agents include, but are not limited to, the following: (a) anti-inflammatory/immunomodulators such as dexamethasone, m-prednisolone, interferon g-1b, leflunomide, sirolimus, tacrolimus, everolimus, pimecrolimus, biolimus (such as Biolimus A7 or A9) mycophenolic acid, mizoribine, cyclosporine, tranilast, and viral proteins; (b) antiproliferatives such as paclitaxel or other taxane derivatives (such as QP-2), actinomycin, methothrexate, angiopeptin, vincristine, mitomycine, statins, CJvIY-C antisense, ABT-578, RestenASE,.Resten-NG_: 2-chloro- deoxyadenosine, and PCNA ribozyme; (c) migration inhibitors/ECM-modulators such as batimastat, prolyl hydroxylase inhibitors, halofuginone, C proteinase inhibitors, and probucol; and (d) agents that promote healing and re-endotheliazation such as BCP671 , VEGF, estradiols (such as 17-beta estradiol (estrogen)), NO donors, EPC antibodies, biorest, ECs, CD-34 antibodies, and advanced coatings.

Any single therapeutic agent or combination of therapeutic agents may be used in the prosthesis. In one example, the therapeutic agent is paclitaxel or a derivative thereof. Paclitaxel may be used to prevent restenosis by preventing chronic inflammation (by preventing the division of affected cells by stabilizing the microtubule function) and by preventing cell migration (by preventing the cell with destructive potential from migrating and accumulating at the injured site).

One or more primer layers, or adhesion promotion layers, may be used with the prosthesis. Such layers may include, for example, silane, acrylate polymer/copolymer, acrylate carboxyl and/or hydroxyl copolymer, polyvinylpyrrolidone/vinylacetate copolymer, olefin acrylic acid copolymer, ethylene acrylic acid copolymer, epoxy polymer, polyethylene glycol, polyethylene oxide, polyvinylpyridine copolymers, polyamide polymers/copolymers polyimide polymers/copolymers, ethylene vinylacetate copolymer and/or polyether sulfones. Finishing

Following the cutting process, the prosthesis may be rough in areas or have sharp or jagged edges, or other surface defects. Mechanical and/or chemical stress may tend to concentrate around those surface defects. Therefore, prostheses properties can often be improved when such surface defects are removed. Surface defects are preferably removed by polishing the prosthesis. Polishing, as used herein, may refer to any type of polishing including, but not limited to, electro- polishing, mechanical polishing, chemical polishing, slurry polishing, as well as filing, tumbling in fine media buffing, grinding, or any other suitable method. In one example, polishing of the prosthesis includes electro-polishing.

Electro-polishing is the electrolytic removal of a metal in a preferably highly ionic solution by means of electrical potential and current. Electro-polishing may be used to smooth, polish, de-burr or clean an electrically conductive material. It may remove stress concentrations by selectively removing surface defects on metal surfaces, thereby making the material stronger. Electro-polishing can also improve corrosion resistance and remove hydrogen from the surface of the stent.

The electro-polishing process preferably begins with the preparation of the prosthesis by cleaning it, which can remove non-conductive material from the prosthesis surface. Oils, glues and other substances are possible contaminants. Then, the prosthesis may be electro-polished by placing it in an acid bath, preferably a phosphoric and sulfuric acid solution, and connecting the positive lead of a DC power supply to the prosthesis and a negative lead to a cathode. Post-treatment preferably involves placing the prosthesis in a nitric acid rinse followed by a water rinse. Delivery of Prostheses

The prostheses of the present invention are preferably configured for endoluminal delivery to a body vessel. For example, a prosthesis is compressed to a delivery configuration within a retaining sheath that is part of a delivery system, such as a catheter-based system. Upon delivery, the prosthesis can be expanded, for example, by inflating a balloon from inside the prosthesis. The delivery configuration can be maintained prior to deployment of the prosthesis by any suitable means, including a sheath, a suture, a tube or other restraining material around all or part of the compressed prosthesis, or other methods.

Prostheses can be deployed in a body lumen by any means appropriate to their design. The prostheses of the present invention can be adapted for deployment using conventional methods known in the art and employing percutaneous transluminal catheter devices. The prostheses are designed for deployment by any of a variety of in situ expansion means.

In one embodiment, the prostheses is a self-expanding stent. In this example, the stent is mounted onto a catheter that holds the prosthesis as it is delivered through the body vessel and then releases the prosthesis and allows it to self-expand into contact with the body vessel walls. This deployment is effected after the stent has been introduced percutaneously, transported transluminal^ and positioned at a desired location by means of the catheter. The self-expanding stent may be deployed according to well-known deployment techniques for self-expanding medical devices. For example, the stent may be positioned at the distal end of a catheter with a removable sheath or sleeve placed over the stent to hold the stent in a contracted state with a relatively small diameter. The prosthesis may then be implanted at the point of treatment by advancing the catheter over a guidewire to the location of the treatment and then withdrawing the sleeve from over the prosthesis. The stent will automatically expand and exert pressure on the wall of the blood vessel at the site of treatment. The catheter, sleeve, and guidewire may then be removed from the patient.

In some embodiments, a bioabsorbable suture or sheath can be used to maintain a self-expanding prosthesis in a compressed configuration both prior to and after deployment. As the bioabsorbable sheath or suture is degraded by the body after deployment, the prosthesis can expand within the body vessel. In some examples, a portion of the prosthesis can be restrained with a bioabsorbable material and another portion allowed to expand immediately upon implantation.

In another embodiment, the prosthesis is first positioned to surround a portion of an inflatable balloon catheter. The prosthesis, with the balloon catheter inside is configured at a first, collapsed diameter. The device and the inflatable balloon are percutaneously introduced into a body vessel, following a previously positioned guidewire. The prosthesis may be tracked by a fluoroscope, until the balloon portion and associated device are positioned within the body vessel at the point where the prosthesis is to be placed. Thereafter, the balloon is inflated and the prosthesis is expanded by the balloon portion from the collapsed diameter to a second expanded diameter. After the prosthesis has been expanded to the desired final expanded diameter, the balloon is deflated and the catheter is withdrawn, leaving the prosthesis in place. The prosthesis may be covered by a removable sheath during delivery to protect both the prosthesis and the vessels.

Throughout this specification various indications have been given as to preferred and alternative embodiments of the invention. However, it should be understood that the invention is not limited to any one of these. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the appended claims, including all equivalents, that are intended to define the scope of this invention.

The features of the various embodiments and modifications described may be combined or substituted as desired.

Claims

1. A method of producing a radially expandable prosthesis, comprising: providing a tubular member having an outer diameter; cutting a pattern in the tubular member to provide a tubular prosthesis where the tubular prosthesis is adapted to have a compressed diameter for endoluminal delivery and an expanded diameter for use upon implantation; where the tubular member outer diameter is at least as great as the prosthesis expanded diameter.

2. The method of claim 1 , wherein said continuous pattern is a zigzag shape.

3. The method of claim 2, wherein said zigzag shape comprises apexes and struts, said apexes comprising a smaller width than said strut.

4. The method of any preceding claim, where said tubular member is cut with a laser.

5. The method of any preceding claim, wherein said pattern comprises anchoring members.

6. The method of claim 5, wherein said anchoring members comprise integral barbs.

7. The method of any preceding claim, wherein said pattern further comprises notches.

8. The method of any preceding claim, further comprising providing a graft material and suturing said prosthesis to said graft material.

9. The method of any preceding claim, further comprising forming at least one cavity in said prosthesis.

10. The method of claim 9, wherein the at least one cavity is at least partially loaded with a therapeutic agent.

11. The method of claim 10, wherein the therapeutic agent is selected from the group consisting of anti-inflammatory/immunomodulators, antiprofileratives, migration inhibitors/ECM-modulators, and agents that promote healing.

12. The method of claim 9, wherein the at least one cavity is at least partially loaded with a radiopaque material.

13. The method of any preceding claim, wherein the tubular member comprises material selected from the group consisting of stainless steel, nitinol, tantalum, a nonmagnetic nickεl-eobalt-εhromium-molybdenum alloy, platinum, titanium, a suitable biocompatible alloy, a suitable biocompatible material, and a combination thereof.

14. The method of any preceding claim, further comprising polishing said prosthesis.

15. A method of claim 14, wherein said polishing comprises electro-polishing.

16. The method of any preceding claim, further comprising coating said prosthesis with a therapeutic agent.

17. The method of claim 16, wherein the therapeutic agent is selected from the group consisting of anti-inflammatory/immunomodulators, antiproliferatives, migration inhibitors/ECM-modulators, and agents that promote healing.

18. The method of claim 17, wherein said therapeutic agent comprises paclitaxel or a paclitaxel derivative.

19. A method according to any preceding claim, wherein the prosthesis is a stent member and the continuous pattern is cut around the tubular member to form a closed loop.

20. A method of producing a radially expandable stent, comprising: providing a tubular member having an outer diameter; laser cutting a zigzag pattern comprising integral barbs, apexes, and struts to provide a zigzg stent; wherein the zigzag stent is adapted to have a compressed diameter for endoluminal delivery and an expanded diameter for use upon implantation; wherein said apexes have a width less than said struts; wherein said tubular member outer diameter is at least as great as the expanded diameter of the stent.

21. A method of providing a stent comprising: providing a tubular member, and cutting a zigzag pattern comprising apexes and struts to produce a zigzag stent, wherein said apexes have a width less than said struts.

22. A zigzag stent comprising struts interconnected by apexes, wherein said apexes have a width less than said struts.

23. A method of producing a prosthesis comprising: providing a tubular member of a first material; coating the tubular- member with at least one-second material; and cutting a pattern in said coated tubular member to provide a tubular prosthesis.

24. A Z-stent member comprising a first layer covered by a second layer comprising fibres, the z-stent member having a zigzag configuration comprising apexes and struts, wherein the fibres are laid or wound substantially parallel to half of the struts.

25. A method of producing a stent member comprising: providing a tubular member; and cutting a pattern in said tubular member to produce a stent member, wherein barbs are incorporated in said pattern.

26. A method of producing a stent member comprising: providing a tubular member; and cutting a pattern in said tubular member to produce a stent member, wherein notches along the stent member are incorporated in said pattern.