Method of making a catheter balloon

A method of forming an expandable member for a medical device, and particularly a balloon for a catheter, in which extruded tubing is first expanded in a continuous or a semi-continuous process to form expanded tubing, and then the expanded tubing is further expanded in a balloon mold to form the catheter balloon. The method generally includes expanding a long length of tubing from a first inner and outer diameter to a second larger inner and outer diameter, to form expanded tubing having an expanded intermediate diameter, and processing the expanded tubing to form a plurality of expanded intermediate diameter tube segments, each segment having a length significantly shorter than the length of the expanded tubing. One of the segments is then placed in an inner chamber of a balloon mold, and expanded in the balloon mold to form a balloon for a catheter.