Systems and methods for manufacturing 3d printed medical devices

An additive manufacturing system comprising:

• a heating cartridge extending from a proximal side to a distal side and comprising a substrate inlet port at the proximal side and a substrate outlet port at the distal side, the heating cartridge defining an interior volume and a substrate channel extending through the interior volume from the proximal side to the distal side, wherein the heating cartridge defines a first filament port in fluid communication with the interior volume to receive the first filament;
• a heating element thermally coupled to the heating cartridge to heat the interior volume;
• a filament handling system comprising one or more motors to feed at least a first filament through the first filament port into the interior volume;
• a substrate handling system comprising:
• a head stock comprising a distal clamp to secure a distal portion of an elongate substrate, wherein the elongate substrate is positioned to pass through the substrate channel when secured by the head stock;
• and
• one or more motors to translate or rotate one or both of the elongate substrate when secured by the head stock and the heating cartridge relative to one another;
• a controller operably coupled to the heating element, one or more motors of the filament handling system, and one or more motors of the substrate handling system, the controller configured to:
• activate the heating element to melt any portion of the first filament in the interior volume;
• control the one or more motors of the filament handling system to selectively control the feeding of the first filament into the interior volume;
• and
• control one or more motors of the substrate handling system to move one or both of the elongate substrate and the heating cartridge relative to one another in at least a longitudinal direction to form an elongate catheter jacket around the elongate substrate, wherein the catheter jacket comprises material from the first filament;
• and
• a shutter comprising a body portion defining a channel spaced longitudinally from the substrate outlet port of the heating cartridge, wherein the shutter is adapted to be selectively adjusted to modify a size and/or shape of the substrate outlet port and engage the catheter jacket.

A method for additive manufacturing of an implantable medical device, the method comprising:

• feeding a substrate through a substrate channel in a heating cartridge, the substrate channel in fluid communication with an interior cavity of the heating cartridge;
• feeding at least a first filament through a filament port into the interior cavity;
• melting the first filament in the interior cavity;
• moving the heating cartridge relative to the substrate at least in a longitudinal direction to form a jacket comprising material from at least the first filament;
• and
• altering the jacket to define jacket features.