A method of forming an introducer sheath having a crease-free tapered distal tip portion. A mandrel is provided having an outer configuration comprising an elongated body and a tapered distal tip portion. A generally tubular inner liner comprising heat shrinkable PTFE, is positioned over the mandrel. The inner liner is heat shrunk to the outer configuration of the mandrel, in a manner that avoids the formation of creases along the inner diameter of the liner. A reinforcing member is positioned over a length of the inner liner, and an outer jacket is positioned over the reinforcing member and the inner liner. The liner, reinforcing member, and outer jacket are heated in a heat shrink enclosure, whereby the outer jacket melts and bonds to an outer surface of the inner liner.