Systems and methods for making and using radially-aligned segmented electrodes for leads of electrical stimulation systems

A method of forming a lead for a stimulation device, the method comprising:

• forming a plurality of pre-electrodes, wherein each of the pre-electrodes is formed in the shape of a ring, wherein each of the plurality of pre-electrodes comprises at least two thin-walled portions separated by at least two thick-walled portions, wherein at least two of the plurality of pre-electrodes each comprise a first tab disposed on one of the at least two thick-walled portions, wherein each of the first tabs comprises a guide feature;
• disposing the plurality of pre-electrodes near a distal end of a lead body;
• joining at least one conductor to each thick-walled portion of each of the plurality of pre-electrodes such that at least one of the at least one conductor extends through each of the guide features, thereby radially aligning the guide features along a length of the lead body;
• and
• grinding the plurality of pre-electrodes to remove the thin-walled portions of each of the plurality of pre-electrode to form a plurality of segmented electrodes from the thick-walled portions of each of the plurality of pre-electrodes.

An electrical stimulation lead assembly comprising:

• an elongated lead body having a distal end, a proximal end, a length, a circumference, and an outer surface, the lead body configured and arranged for insertion into a patient;
• a membrane coupleable to the distal end of the lead body, the membrane comprising a rear face coupleable to the lead body, a front face opposite to the rear face, and a width, wherein when the membrane is coupled to the distal end of the lead body, the membrane is disposed over at least a portion of the outer surface of the distal end of the lead body such that the width of the membrane wraps around the circumference of the lead;
• a plurality of electrodes disposed on the front face of the membrane;
• and
• a plurality of conductors extending along the length of the lead body from the proximal end to the plurality of spaced-apart electrodes, wherein each of the conductors is electrically coupled to at least one of the plurality of electrodes.

A method of forming a lead for a stimulation device comprising:

• disposing a plurality of electrodes along a front face of a membrane;
• coupling a rear face of the membrane to an outer surface of a distal end of an elongated lead body such that the rear face of the membrane conforms to a shape of the outer surface of the lead body and a width of the membrane wraps around the outer surface of the lead body;
• and
• coupling individual conductors extending along a length of the lead body to each of the plurality of electrodes.