Basket assembly with atraumatic tip electrode and methods of making thereof

A medical probe, comprising:

• a tubular shaft extending along a longitudinal axis;
• and
• an expandable basket assembly connected to a distal end of the tubular shaft and comprising:
• a single unitary structure comprising a plurality of spines converging at a central spine intersection, the central spine intersection being positioned along the longitudinal axis at a distal end of the expandable basket assembly, the plurality of spines comprising a first layer and a second layer attached to the first layer and comprising a central cutout about the central spine intersection that exposes the first layer at the central spine intersection;
• one or more extrusion layers at least partially covering each spine;
• and
• a central electrode attached to the first layer at the central spine intersection.

A method of constructing a medical probe, the method comprising:

• cutting a planar sheet of a second material to form a second layer of a plurality of spines having a central spine intersection;
• cutting a center hole at the central spine intersection;
• overmolding a first material on the second layer forming a first layer;
• cutting a cutout in the first layer at the central spine intersection to expose a portion of the second layer at the central spine intersection;
• and
• inserting a central electrode into the center hole.