Mold for forming solder distal tip for guidewire

A method for forming a solder distal tip of predetermined shape on a distal end of a guidewire, comprising:

• providing a mold having a cavity;
• placing solder material into the cavity;
• placing the mold into a heating apparatus and heating the mold until the solder becomes molten;
• submerging the distal end of the guidewire into the molten solder in the cavity;
• cooling the mold to solidify the solder and form a solder tip at the distal end of the guidewire;
• and
• removing the solder tip and guidewire from the mold.

A mold for forming a solder distal tip of predetermined shape on a distal end of a guidewire, comprising:

• a mold blank having a cavity with an opening configured to receive the distal end of the guidewire and a distal end of a wire coil surrounding the distal end of the guidewire;
• the cavity defining a volume for receiving solder and heating the solder to a molten state;
• the mold being formed of a material able to withstand a temperature required to melt the solder;
• the cavity defining a specific geometry for receiving the distal end of the guidewire and the distal end of the wire coil into the cavity and allowing the molten solder to flow onto the distal end of the guidewire and the distal end of the wire coil to form a solder joint to attach to attach the distal end of the wire coil to the distal end of the guidewire;
• and
• wherein the cavity has a bullet shape with a cylindrical body, tapered nose and blunt tip.