Methods for fabricating segmented electrodes

A method of forming an electrode assembly, the method comprising:

• performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, wherein the initial electrode includes i) a plurality of contact bodies having a first thickness and ii) at least one retaining tab extending axially from each contact body, the at least one retaining tab having a same inner diameter as the plurality of contact bodies and having a second thickness smaller than the first thickness;
• coupling the initial electrode to a lead body;
• and
• removing portions of the initial electrode using a centerless grinding process to form a segmented electrode on the lead body, the segmented electrode including a plurality of circumferentially spaced contacts.

A method of forming an implantable stimulation lead, the method comprising:

• performing a series of progressive die stamping operations on a foil sheet of material to form an initial electrode, wherein the initial electrode includes i) a plurality of contact bodies having a first thickness and ii) at least one retaining tab extending axially from each contact body, the at least one retaining tab having a same inner diameter as the plurality of contact bodies and having a second thickness smaller than the first thickness;
• coupling the initial electrode to a lead body;
• removing portions of the initial electrode using a centerless grinding process to form a segmented electrode on the lead body, the segmented electrode including a plurality of circumferentially spaced contacts;
• and
• electrically connecting each of the plurality of circumferentially spaced contacts to associated conductors of the lead body to form the implantable stimulation lead.