Patent ID: 7025923

Claim:
A method of forming a medical component having a cross-section shape that includes at least one concave portion, comprising the steps of: heating a portion of a sheet of a selected material to a malleable temperature to form a malleable heated portion of the sheet; forming a protrusion in the heated portion while the heated portion is malleable, the protrusion having an open proximal end, a distal end, and sidewalls extending between the proximal and distal ends, the sidewalls and distal end defining a first shape of the protrusion; positioning a forming tool in the interior of the protrusion, the forming tool having a shaping portion with a selected shape that is different than the first shape of the protrusion and wherein the forming tool includes a segment having a concave cross-sectional shape; and exerting an inwardly directed force on the protrusion while the heated portion is malleable, the force being sufficient to move a portion of the protrusion inwardly into engagement with the shaping portion so the protrusion changes from the first shape to a second shape that conforms to the selected shape of the forming too's shaping portion and wherein at least part of the protrusion has a cross-sectional shape that conforms with the concave cross-sectional shape.