Abstract Active steering catheters and guidewires for vascular intervention, employing pressure-driven mechanisms, have been studied for their promise of safety, miniaturization capacity, and ease of operation. Manufacturing methods of pressure-driven catheters and guidewires at the microscale is challenging, and suffer from limitations such as low durability, restricted steering shape, cytotoxicity, and applicability. This paper proposes a novel manufacturing method of the hydraulically steerable actuator for micro guidewires utilizing closed molding and a laser-patterned core template. The cylindrical core template composed of stainless steel is employed to ensure biocompatibility and is patterned by femtosecond laser processing with relative errors of up to 15.04%. The proposed method enables a bonding-free manufacturing of the micro actuator which is an eccentric tube with integrated patterns on its inner surface. Trapezoidal patterns are designed to be symmetrically placed in the direction of the eccentricity on the proximal part. The steering shape of the micro actuator is designed by adjusting the geometry of the patterns engraved onto the core template. A steerable actuator of 600 μm diameter with a double bending curvature is manufactured, achieving a maximum bending angle of 132.93 degrees and a steering distance of 9.20 mm. Experiments of selective insertion with the steerable actuator are conducted using the model of cerebral vascular branching, which resembles the human blood flow. The experiment results show that the steerable actuator can navigate through the vascular bifurcations of 4.2 mm and 1.5 mm diameters with branching angles of 112 degrees.
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