Patent ID: 8721826

Claim:
A method of manufacturing a thin-walled tube having a distal steerable portion, comprising: coating a wire with a plastic material; wrapping the coated wire around a mandrel forming a plurality of windings; forming a primary lumen within the first wire windings; the primary lumen having a longitudinal axis; placing a first tube having a secondary lumen and a longitudinal axis on the first wire windings so that the longitudinal axis of the secondary lumen is spaced apart from the longitudinal axis of the primary lumen and the first tube and secondary lumen extend further in length than the first wire windings and primary lumen along the mandrel to form a distal steerable portion; heating the wound coated wire and first tube until the plastic material melts and bonds the windings forming a wire-reinforced tube having a primary lumen and a secondary lumen; inserting a pull-wire into the secondary lumen; removing the mandrel; forming an outer layer of plastic around the windings and the first tube; and winding a second wire to encompass the windings, first tube and outer layer; wherein the step of heating the wound coated wire and first tube includes heating the outer layer to bond the first tube, coated wire and outer layer together.