Process for producing a catheter

A process for producing a catheter comprising:

• providing a catheter shaft having a proximal end, a distal end, an interior, an exterior, a first lumen extending through the shaft and exiting at the distal end, and a second lumen extending at least partially through the shaft and terminating in a port situated upon the exterior;
• situating the distal end of the shaft within a molding device;
• forming in place on the distal end of the shaft within the molding device a unitary component having a first surface, a rigid tip interconnected to an expandable balloon, the unitary component terminating in a distal end at the tip and a proximal end at the balloon, the unitary component having a passageway therethrough and being securely affixed to the distal end of the shaft by being formed in place such that the first lumen and passageway are in alignment with one another;
• folding the proximal end of the unitary component over the rigid tip;
• and
• attaching the proximal end of the unitary component to the exterior such that the first surface of the tip faces the first surface of the expandable balloon and the port is contained within a space formed by the expandable balloon.