Catheter-based interventions are a form of minimally invasive surgery that can decrease hospitalization time and greatly lower patient morbidity compared to traditional methods. However, percutaneous catheter procedures are hindered by a lack of precise tip manipulation when actuation forces are transmitted over the length of the catheter. Active catheters with local shape-memory-alloy (SMA) actuation can potentially provide the desired manipulation of a catheter tip, but hysteresis makes it difficult to control the actuators. A method to integrate small-volume, compliant sensors on an active catheter to provide position feedback for control would greatly improve the viability of SMA-based active catheters. In this work, we describe the design, fabrication, and performance of resistance-based position sensors that are laser-machined from superelastic SMA tubing. Combining simple material models and rapid prototyping, we can develop sensors of appropriate stiffness and sensitivity with simple modifications in sensor geometry. The sensors exhibit excellent linearity over the operating range and are designed to be easily integrated onto an active catheter substrate.
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