Monolithic lead assembly and methods of microfabricating a monolithic lead assembly

A method of manufacturing a monolithic thin-film cable assembly, the thin-film cable assembly comprising:

• a proximal end;
• a distal end;
• a supporting structure that extends from the proximal end to the distal end, wherein the supporting structure is comprised of one or more layers of dielectric material;
• a plurality of conductive traces formed on a portion of the supporting structure;
• and
• a housing,
• wherein the portion of the supporting structure has a spiral shape comprising two or more turns having a pitch between each of the turns in a range of 10 μm to 1 cm, and
• wherein the housing completely encases at least a portion of the supporting structure and the one or more conductive traces and partially encases an electrode assembly
• the method comprising:
• forming a first polymer layer on a wafer or panel of substrate;
• forming a plurality of conductive traces on a first portion of the first polymer layer, wherein the forming the plurality of conductive traces comprises depositing a conductive material in a spiral pattern with two or more turns on the first portion of the first polymer layer;
• forming a wiring layer on a second portion of the first polymer layer, wherein the forming the wiring layer comprises depositing the conductive material in electrical contact with the plurality of conductive traces;
• depositing a second polymer layer on the wiring layer and the second portion of the first polymer layer;
• forming at least one electrode on the second polymer layer such that the at least one electrode is in electrical contact with at least a portion of a top surface of the wiring layer;
• and
• cutting the monolithic thin-film lead assembly from the first polymer layer, wherein the monolithic thin-film lead assembly comprises the plurality of conductive traces in the spiral pattern on the first polymer layer and the at least one electrode on the second polymer layer electrically connected to the plurality of conductive traces.