Patent ID: 8022331

Claim:
A method of manufacturing a medical device, comprising the steps of: providing a core wire having a proximal section and a distal section, the distal section of the core wire formed from a metal or metal alloy, the distal section including a widened diameter portion at a distal end of the core wire; providing a tubular body member having a proximal portion and a distal portion, the tubular body defining a lumen therethrough having an inner diameter configured to fit over an outer diameter of the widened diameter portion; attaching a tip to the distal portion of the tubular member to form a distal cap member comprising the tubular body member and the tip, the distal cap member formed from a metal or metal alloy that is welding-compatible with the metal or metal alloy of the distal section of the core wire; after forming the distal cap member, inserting the widened diameter portion of the distal section of the core wire into the lumen of the tubular body; and after inserting the widened diameter portion into the lumen, welding the distal cap member to the distal section of the core wire; wherein the widened diameter portion of the distal section of the core wire is a heat sink during the welding.