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Manufacturing processes for apparatus, including slotted hypotube, for use as a catheter, a guidewire, a catheter sheath for use with catheter introducers or a drug infusion catheter/guidewire are disclosed. The manufacturing process includes creating a pattern of slots or apertures in a flexible me

Manufacturing processes for apparatus, including slotted hypotube, for use as a catheter, a guidewire, a catheter sheath for use with catheter introducers or a drug infusion catheter/guidewire are disclosed. The manufacturing process includes creating a pattern of slots or apertures in a flexible metallic tubular member, by processes including but not limited to, electrostatic discharge machining (EDM), chemical milling, ablation and laser cutting. These slots or apertures may be cut completely or partially through the wall of the flexible metallic tubular member. These manufacturing processes may include the additional step of encasing the flexible metallic member such that a fluid tight seal is formed around the periphery of the tubular member.

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[ What is claimed is:] [1.] A method for producing a flexible tubular medical device comprising:providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;providing a light source;applying a photoresist to at least a portion of the outer

[ What is claimed is:] [1.] A method for producing a flexible tubular medical device comprising:providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;providing a light source;applying a photoresist to at least a portion of the outer surface of the tubular element;providing a pattern mask intermediate the tubular element and the light source;exposing the photoresist by directing light from the light source through the pattern mask, and generating relative movement between the tubular element and the light source such that an exposed pattern and an unexposed pattern are generated on the outer surface of the tubular element;developing the photoresist to remove first regions of the photoresist that correspond to one of the exposed and unexposed patterns; andremoving first portions of the tubular element that correspond to the first regions of the photoresist such that the tubular element is provided with a desired pattern, the desired pattern including a plurality of apertures that extend completely through the tubular element between an inner and outer diameter of the tubular element, the plurality of apertures being arranged and configured for providing the tubular element with a desired flexibility suitable for intravascular operations.