Method of forming a urinary catheter

A method of forming a urinary catheter, the method comprising:

• providing a mould having a mould cavity forming an elongated recess extending in an axial direction from a distal end of the recess to a tip terminating at a proximal end of the recess;
• providing a core inserted into the elongated recess of the mould cavity;
• coupling a flow structure to the mould, with the flow structure comprising a primary melt channel in simultaneous communication with a first secondary melt channel and a second secondary melt channel;
• coupling the first secondary melt channel to a first injection location of the mould cavity and coupling the second secondary melt channel to a second injection location of the mould cavity;
• injecting a polymer melt through the primary melt channel and into the elongated recess around an outer surface of the core;
• controlling a first pressure of the polymer melt in the first secondary melt channel separately and individually from a second pressure of the polymer melt in the second secondary melt channel and reducing stress of the polymer melt along the elongated recess;
• and
• opening the mould, removing the core, and providing a moulded intermittent urinary catheter having an open distal end and a closed proximal tip.