Laminated prosthesis and method of manufacture

A method of manufacturing a self-supporting, tissue expanding item constructed of multiple layers forming a molded flexible, expandable membrane surrounding and defining an interior lumen, said method comprising the steps of:

• (a) applying a fluid material comprised of an orientable polymer to a mandrel;
• (b) draining said fluid material off the mandrel in a first flow direction;
• (c) allowing said fluid material to harden to form a resilient, stretchable first layer on the mandrel;
• (d) applying a second layer of the same said fluid material on said first layer;
• (e) changing the orientation of the mandrel to allow the fluid material to drain off the mandrel in a second flow direction, the second flow direction being at a first angle with respect to said first flow direction;
• (f) allowing the fluid material to harden to form a resilient, stretchable second layer on said first layer;
• (g) applying additional layers of fluid material to said second layer, changing the orientation of the mandrel to allow the fluid material to drain off the mandrel in additional flow directions, each flow direction being at a second angle with respect to the preceding flow direction, and allowing the fluid material to harden to form additional resilient, stretchable layers;
• and
• (h) removing said multi-layered item from said mandrel whereby the cooperation of the different directional layers forms a strengthened, multi-layered, molded item.

A method of manufacturing a self-supporting, tissue expanding item constructed of multiple, layers forming a flexible, expandable and self-supporting, molded membrane surrounding and defining an interior lumen, said method comprising the steps of:

• (a) applying a fluid material comprised of an orientable polymer to a mandrel, said fluid material further containing filaments of a stretchable material and being mixed in said fluid material;
• (b) draining said fluid material off the mandrel in a first flow direction whereby said polymer and said filaments are generally oriented in said first flow direction;
• (c) allowing the fluid material to harden to form a resilient, stretchable first layer on the mandrel;
• (d) applying a second layer of the same said fluid material on the first layer;
• (e) changing the orientation of the mandrel to allow the fluid material to drain off the mandrel in a second flow direction whereby said polymer and said filaments comprising said second layer are generally oriented in said second flow direction, the second flow direction being at a first angle with respect to said first flow direction;
• (f) allowing the fluid material to harden to form a resilient, stretchable second layer on the hardened first layer;
• (g) applying additional layers of said fluid material to the second hardened layer, changing the orientation of the mandrel to allow the fluid material to drain off the mandrel in additional flow directions, each flow direction being at an angle with respect to the preceding flow direction, and allowing the fluid material to harden to form additional resilient, stretchable layers;
• and
• (h) removing said multi-layered item from said mandrel whereby the cooperation of the different directional layers forms a strengthened, multi-layered, molded item.