Pre-curved cochlear implant electrode array

A method of manufacturing an implantable electrode array including a carrier having a first molded layer and at least a second molded layer, the carrier having a proximal end and a distal end, the method comprising:

• moulding the first layer of the carrier in a first spiral-shaped mould having a first degree of curvature;
• and
• moulding the second layer of the carrier after moulding the first layer over at least a portion of the surface of the first layer such that said carrier is formed in a second configuration in which the array can apply tissue stimulation to the cochlea and is manipulable to a first configuration that allows the carrier to be insertable into the cochlea of an implantee,
• wherein at least one of the layers has at least one electrode moulded therein, and wherein the at least one electrode is exposed to an ambient environment of the implantable electrode array after the moulding of the second layer and prior to insertion into a recipient.

An implantable electrode array comprising a carrier that is insertable into a cochlea of an implantee, the carrier having a proximal end and a distal end and comprising:

• a first layer of a resiliently flexible material;
• a second layer of a resiliently flexible material, a first surface of the first layer and a second surface of the second layer bifurcating the second layer from the first layer extending parallel to one another over an arc, a portion of the second surface of the second layer having a shape conforming to a shape of a portion of the first surface of the first layer;
• and
• a plurality of electrodes, at least one of the electrodes being in direct contact with the first layer,
• wherein the carrier is formed in a second configuration in which the array can apply tissue stimulation to the cochlea and is manipulable to a first configuration that allows the carrier to be insertable into the cochlea of an implantee.