Patent ID: 8316537

Claim:
A method of fabricating a stimulation lead for applying electrical pulses to tissue of a patient, the method comprising: providing a lead body assembly, the lead body assembly comprising: first insulative material defining at least one interior passageway extending from a proximal portion to a distal portion of the lead body assembly; a plurality of conductors; a plurality of electrodes at the distal portion; and a plurality of terminals at the proximal portion, wherein the plurality of electrodes are electrically coupled to the plurality of terminals through the plurality of conductors; overmolding at least the distal portion of the lead body assembly with second insulative material to form an intermediate assembly, wherein (i) the first and second insulative materials have consistent mechanical properties such that the overmolding causes the first insulative material to fuse together with the second insulative material and (ii) the overmolding causes filling of the at least one interior passageway at the distal portion with an insulative material; and removing the insulative material in excess of a prescribed diameter from at least the distal portion of the intermediate assembly.