Systems and methods of forming a continuous reinforced catheter shaft

A sheath, comprising:

• a liner;
• a plurality of wire frames coiled around the liner, each wire frame of the plurality of wire frame having a proximal portion and a distal portion having the reinforcing wire coiled more densely than the proximal portion;
• an interim portion of wire coiled at least partially around the liner and connecting the distal portion of a first wire frame of the plurality of wire frames to the proximal portion of a second wire frame of the plurality of wire frames adjacent to the first wire frame such that the distal portion of the first wire frame is spaced from the proximal portion of the second wire frame;
• and
• a jacket secured over the plurality of coiled wire frames and the interim portion of wire.

A system for coiling reinforcing wire around a liner, the system comprising:

• a first spool having a liner rolled thereon, the liner having a metal wire disposed therein;
• a spool of reinforcing wire;
• an assembly configured to coil the reinforcing wire on at least the portion of the liner unrolled from the first spool to form (1) a plurality of coiled wire frames each having a proximal portion and a distal portion having the reinforcing wire coiled more densely than the proximal portion, and (2) an interim portion of the reinforcing wire coiled between the distal portion of a first wire frame of the plurality of wire frames and a proximal portion of a second wire frame of the plurality of wire frames adjacent to the first wire frame such that the distal portion of the first wire frame is spaced from the proximal portion of the second wire frame;
• a jacket assembly configured to secure a jacket over the plurality of coiled wire frames and the interim portion of the reinforcing wire coiled on the portion of the liner to form a continuous shaft having the plurality of coiled wire frames;
• and
• an additional spool positioned to roll the continuous shaft thereon.