Methods of forming sheared lubricious coated medical devices

A method of forming a coated medical device, the method comprising:

• forming a lubricious coating solution or suspension, wherein the lubricious coating suspension comprises an ultra-high molecular weight polyethylene (UHMWPE) and solvent, wherein the lubricious coating solution or suspension is per- and polyfluoroalkyl substance (PFAS)-free;
• applying the lubricious coating solution to a substrate to form a coated medical device;
• and
• applying a shear stress to the coated medical device to form a sheared lubricious coated medical device by contacting an exterior surface of the coated medical article with a plurality of passes of a polymeric member.