Implantable thin film devices

A method of manufacturing an implantable thin film stimulation lead for patient treatment, the method comprising:

• forming an elongated three-dimensional insulator as a tubular structure with a non-flat profile, the insulator having an inner surface and an outer surface, the insulator further having a distal end and a proximal end;
• forming a layer of conductive traces disposed on the inner surface of the insulator and defining a trace pattern, the layer of conductive traces fabricated on the inner surface of the insulator using biocompatible metallization;
• forming an insulating layer having an outer surface and an inner surface, the insulating layer applied over the layer of conductive traces with intimate contact between the inner surface of the insulator and the inner surface of the insulating layer outside of the trace pattern;
• forming a plurality of electrodes positioned at the distal end of the insulator, the plurality of electrodes being disposed on at least one of the outer surface of the insulator or the outer surface of the insulating layer;
• and
• forming a plurality of connectors positioned at the proximal end of the insulator, the plurality of connectors being disposed on at least one of the outer surface of the insulator or the outer surface of the insulating layer, the plurality of electrodes and the plurality of connectors being electrically connected to the layer of conductive traces forming a flexible circuit, wherein an electrical connection between the plurality of electrodes and the layer of conductive traces is established through one or more vias filled with conductive material, the one or more vias formed at the distal end in at least one of the outer surface of the insulator or the outer surface of the insulating layer, and wherein an electrical connection between the plurality of connectors and the layer of conductive traces is established through one or more vias filled with conductive material, the one or more vies formed at the proximal end in at least one of the outer surface of the insulator or the outer surface of the insulating layer.