Medical devices with amorphous metals and methods therefor

Abstract

Medical devices made at least in part of amorphous metals or alloys are provided. Certain embodiments include filters, stents, guidewires, snares, and coils comprised of amorphous metal. Methods of forming the medical devices, including methods of shape setting amorphous metals or alloys into components of medical devices are also provided. Methods of using amorphous metal medical devices are also provided.

1 . A method of forming a shape set medical device comprising the steps of:
 providing a structure including an amorphous metal; and   shape setting the structure to at least partially convert the amorphous metal into crystalline metal to impart crystalline properties to the medical device such that the structure includes between about 0.5 volume percent to about 75 volume percent crystalline portions, wherein the crystalline portions form the medical device.   
     
     
         2 . The method of  claim 1 , wherein the step of shape setting the structure includes applying heat to the structure. 
     
     
         3 . The method of  claim 2 , wherein the step of shape setting the structure includes heating the structure to a temperature about or above a glass transition temperature of the amorphous metal. 
     
     
         4 . The method of  claim 1 , wherein the step of shape setting the structure includes forming the crystalline portions into a stent. 
     
     
         5 . The method of  claim 4 , wherein the step of shape setting the structure includes forming the crystalline portions into a self-expanding stent. 
     
     
         6 . The method of  claim 4 , wherein the step of shape setting the structure includes forming the crystalline portions into a stent configured and dimensioned for expansion by a balloon. 
     
     
         7 . The method of  claim 1 , wherein the step of shape setting the structure includes forming the crystalline portions into a filter. 
     
     
         8 . The method of  claim 7 , wherein the step of shape setting the structure includes forming the crystalline portions into a braided filter. 
     
     
         9 . The method of  claim 1 , wherein the step of shape setting the structure includes forming the structure to include one or more amorphous metal filaments having a diameter between about 0.010 inches (0.25 mm) and about 0.00050 inches (0.013 mm). 
     
     
         10 . The method of  claim 1  further including the step of applying a coating to at least a portion of the medical device. 
     
     
         11 . The method of  claim 10 , wherein the step of applying a coating to at least a portion of the medical device includes applying one or more of a radiopaque coating, a drug coating, an active agent release coating, a biocompatible coating, or a lubricious coating. 
     
     
         12 . The method of  claim 1 , wherein the step of shape setting the structure includes forming the structure in a manner facilitating imaging of the medical device under MRI. 
     
     
         13 . The method of  claim 1 , wherein the step of shape setting the structure includes annealing the amorphous metal. 
     
     
         14 . The method of  claim 13 , wherein the step of shape setting the structure includes annealing the amorphous metal in a manner substantially maintaining a shape of the structure. 
     
     
         15 . A method of performing a surgical procedure comprising the steps of:
 inserting a shape set medical device into a body in a collapsed configuration, wherein the medical device includes an amorphous metal comprising between about 0.5 volume percent to about 75 volume percent crystalline portions; and   expanding the medical device.   
     
     
         16 . The method of  claim 15 , wherein the step of inserting a shape set medical device includes inserting a stent into the body. 
     
     
         17 . The method of  claim 16 , wherein the step of inserting a shape set medical device includes inserting a self-expanding stent into the body. 
     
     
         18 . The method of  claim 16  further including the step of expanding the stent using a balloon. 
     
     
         19 . The method of  claim 15 , wherein the step of inserting a shape set medical device includes inserting a filter into the body. 
     
     
         20 . The method of  claim 15  further including the step of visualizing the medical device using MRI.