A launching member having a flexible portion to accommodate the load during the surgical firing stroke.

Abstract

A surgical stapling assembly is disclosed. The surgical stapling assembly may include a first jaw, a second jaw, an articulation joint, a closure drive with a first flexible rotation drive extending through the articulation joint, and a firing drive with a second flexible rotation drive extending through the articulation joint and rotatable independently of the first flexible rotation drive. The surgical stapling assembly may further include a 3D printed component. The 3D printed component may include a plastic body and one or more metal substrates having interlocking features embedded in the plastic body. The surgical stapling assembly may include a firing member having a flexible portion configured to bend more easily than adjacent portions of the firing member.

Description

Background Art

[0001] The present invention relates to surgical instruments and, in various configurations, surgical stapling and cutting instruments, end effectors, and staple cartridges for use therewith, which are designed to staple and cut tissue.

Brief Description of the Drawings

[0002] The various features of the embodiments described herein, together with their advantages, can be understood in accordance with the following description taken in conjunction with the following accompanying drawings. [Figure 1] FIG. 1 is a perspective view of a surgical stapling instrument including a handle, a shaft assembly, and an end effector according to at least one aspect of the present disclosure. [Figure 2] FIG. 2 is a perspective view of a portion of the end effector and shaft assembly of the surgical stapling instrument of FIG. 1, wherein the end effector is shown in a linear or non-articulated configuration according to at least one aspect of the present disclosure. [Figure 3] FIG. 3 is a perspective view of a portion of the end effector and shaft assembly of the surgical stapling instrument of FIG. 1, wherein the end effector is shown in an articulated configuration according to at least one aspect of the present disclosure. [Figure 4] FIG. 4 is an exploded perspective view of a portion of the end effector and shaft assembly of the surgical stapling instrument of FIG. 1 according to at least one aspect of the present disclosure. [Figure 5] FIG. 5 is a cross-sectional elevation view of a portion of the end effector and shaft assembly of the surgical stapling instrument of FIG. 1, wherein the end effector is shown in an un-fired clamp configuration according to at least one aspect of the present disclosure. [Figure 6] FIG. 6 is a plan view of a portion of the end effector and shaft assembly of the surgical stapling instrument of FIG. 1 according to at least one aspect of the present disclosure. [Figure 7] It should be noted that the original text seems to be missing some figure number references in the description of FIGS. 2 - 6. I have added the corresponding figure number descriptions according to the context for a more complete translation. If this is not in line with your requirements, please let me know.This is a cross-sectional elevation view of a portion of the end effector and shaft assembly of Figure 1 along the cutting line 6-6 of Figure 6, in which the end effector is shown in an open configuration, according to at least one aspect of the present disclosure. [Figure 8] This is a cross-sectional elevation view of a portion of the end effector and shaft assembly of Figure 1 along the cutting line 7-7 of Figure 6, in which the end effector is shown in a clamp configuration, according to at least one aspect of the present disclosure. [Figure 9] A perspective view of a surgical staple fastening assembly comprising a shaft assembly, Figure 1, and an end effector, the end effector being attached to the shaft assembly by an articulated joint, according to at least one aspect of the present disclosure. [Figure 10] Figure 9 is an exploded perspective view of a surgical staple fastening assembly according to at least one aspect of the present disclosure. [Figure 11] Figure 9 is a cross-sectional elevation view of a surgical staple fastening assembly, shown in a clamp configuration with the end effector not fired, according to at least one aspect of the present disclosure. [Figure 12] A perspective view of a surgical staple fastening assembly comprising a shaft assembly, Figure 1, and an end effector, the end effector being attached to the shaft assembly by an articulated joint, according to at least one aspect of the present disclosure. [Figure 13] Figure 12 is an exploded perspective view of a surgical staple fastening assembly according to at least one aspect of the present disclosure. [Figure 14] Figure 12 is a cross-sectional elevation view of a surgical staple fastening assembly, shown in a clamp configuration with the end effector not fired, according to at least one aspect of the present disclosure. [Figure 15] A perspective view of a surgical staple fastening assembly comprising a shaft assembly, Figure 1, and an end effector, the end effector being attached to the shaft assembly by an articulated joint, according to at least one aspect of the present disclosure. [Figure 16]Figure 15 is an exploded perspective view of a surgical staple fastening assembly according to at least one aspect of the present disclosure. [Figure 17] Figure 15 is a cross-sectional elevation view of a surgical staple fastening assembly, shown in a clamp configuration with the end effector not fired, according to at least one aspect of the present disclosure. [Figure 18] This is a perspective view of a surgical end effector assembly comprising the end effector shown in Figure 1 and a flexible firing drive system, according to at least one aspect of the present disclosure. [Figure 19] Figure 18 is an exploded perspective view of a surgical staple fastening assembly according to at least one aspect of the present disclosure. [Figure 20] Figure 18 is a cross-sectional elevation view of a surgical end effector assembly, in which the surgical end effector assembly is shown in a non-firing clamp configuration according to at least one aspect of the present disclosure. [Figure 21] This is a perspective view of a robotic controller according to at least one aspect of the present disclosure. [Figure 22] This is a perspective view of a robotic arm cart for a robotic surgical system, depicting a manipulator on a robotic arm cart that operably supports a surgical tool, according to at least one aspect of the present disclosure. [Figure 23] Figure 22 is a side view of the manipulator and surgical gripping tool of the surgical arm cart according to at least one aspect of the present disclosure. [Figure 24] These are side elevation views of a launching member according to various embodiments of this disclosure. [Figure 25] This is a side elevation view of the launch member of Figure 24 in an extended configuration according to various aspects of the present disclosure. [Figure 26] This is a cross-sectional elevation view of a part of a surgical instrument, including an expandable knife portion, according to various aspects of the present disclosure. [Figure 27] This is a perspective view of a surgical instrument, including an anvil made of low-durometer material, depicting a surgical instrument in an open configuration according to various aspects of the present disclosure. [Figure 28]A cross-sectional elevation view of a surgical instrument in a closed configuration, depicting the surgical instrument according to various aspects of the present disclosure. [Figure 29] A perspective view of a firing member for use with a surgical instrument, according to various aspects of the present disclosure. [Figure 30] An enlarged view of a portion of the firing member of FIG. 29, according to various aspects of the present disclosure. [Figure 31] A partial cross-sectional perspective view of a portion of the firing member of FIG. 29, according to various aspects of the present disclosure. [Figure 32] A side elevation view of a firing member for use with a surgical instrument, depicting the firing member in a first configuration, according to various aspects of the present disclosure. [Figure 33] A side elevation view of the firing member of FIG. 32 in a second configuration, in which the firing member is deformed from a first configuration to a loading configuration, depicting a channel and an anvil portion for an environmental structure in dashed lines, according to various aspects of the present disclosure. [Figure 34] A perspective view of a firing member for use with a surgical instrument, according to various aspects of the present disclosure. [Figure 35] A side elevation view of the firing member of FIG. 34, according to various aspects of the present disclosure. [Figure 36] A front elevation view of the firing member of FIG. 34, according to various aspects of the present disclosure. [Figure 37] A graphical representation of representative forces applied to the firing member of FIG. 34 during a firing stroke, according to various aspects of the present disclosure. [Figure 38] A perspective view of a firing member for use with a surgical instrument, according to various aspects of the present disclosure. [Figure 39] A side elevation view of the firing member of FIG. 38, according to various aspects of the present disclosure. [Figure 40] A perspective view of a model structure before force loading, indicated by phantom lines, and during force loading, indicated by solid lines, according to various aspects of the present disclosure. [Figure 41] An elevation view of a channel retainer having a substrate portion, according to various aspects of the present disclosure. [Figure 42]Perspective exploded view of a portion of the substrate element of FIG. 41, according to various aspects of the present disclosure. [Figure 43] Cross-sectional elevation view of the channel retainer of FIG. 41 along the plane shown in FIG. 41, according to various aspects of the present disclosure. [Figure 44] Perspective view of a portion of a surgical instrument comprising an overmolded sleeve depicted in phantom lines, further depicting a firing bar support within the overmolded sleeve, according to various aspects of the present disclosure. [Figure 45] Planar view of a portion of the surgical instrument of FIG. 44, depicted in phantom lines for the overmolded sleeve and further depicting the instrument in an articulating configuration, according to various aspects of the present disclosure. [Figure 46] Side elevation view of an anvil for use with a surgical instrument, according to various aspects of the present disclosure.

[0003] Throughout multiple drawings, corresponding reference numerals indicate corresponding parts. The examples described herein are illustrative of various embodiments of the present invention in one form, and such examples should not be construed as limiting the scope of the present invention in any way.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The applicant of the present application owns the following U.S. patent applications filed on the same day as the present application, and each of these is hereby incorporated by reference in its entirety. - U.S. Patent Application, Invention Title "METHOD OF USING A POWERED STAPLING DEVICE", Attorney Docket No. END9298USNP1 / 200859-1M - U.S. Patent Application, Invention Title "SURGICAL STAPLING ASSEMBLY COMPRISING NONPLANAR STAPLES AND PLANAR STAPLES", Attorney Docket No. END9298USNP2 / 200859-2 - US Patent Application, Invention Title: "SURGICAL STAPLE CARTRIDGE COMPRISING LONGITUDINAL SUPPORT BEAM", Agent Reference Number: END9298USNP3 / 200859-3 - U.S. Patent Application, Title of Invention: "ROTARY-DRIVEN SURGICAL STAPLING ASSEMBLY COMPRISING ECCENTRICALLY DRIVEN FIRING MEMBER", Agent Reference Number: END9298USNP4 / 200859-4 - U.S. Patent Application, Title of Invention: "ROTARY-DRIVEN SURGICAL STAPLING ASSEMBLY COMPRISING A FLOATABLE COMPONENT", Agent Reference Number: END9298USNP5 / 200859-5 - U.S. Patent Application, Title of Invention: "DRIVERS FOR FASTENER CARTRIDGE ASSEMBLIES HAVING ROTARY DRIVE SCREWS", Agent Reference Number: END9298USNP6 / 200859-6 - U.S. Patent Application, Title of Invention: "MATING FEATURES BETWEEN DRIVERS AND UNDERSIDE OF A CARTRIDGE DECK", Agent Reference Number: END9298USNP7 / 200859-7 - U.S. Patent Application, Title of Invention: "LEVERAGING SURFACES FOR CARTRIDGE INSTALLATION", Agent Reference Number: END9298USNP8 / 200859-8 - US Patent Application, Title of Invention: "FASTENER CARTRIDGE WITH NON-REPEATING FASTENER ROWS", Agent Reference Number: END9298USNP9 / 200859-9 - US Patent Application, Invention Title: "STAPLING ASSEMBLY COMPONENTS HAVING METAL SUBSTRATES AND PLASTIC BODIES", Agent Reference Number: END9298USNP11 / 200859-11 - U.S. Patent Application, Title of Invention: "MULTI-AXIS PIVOT JOINTS FOR SURGICAL INSTRUMENTS AND METHODS OF MANUFACTURING SAME", Agent Reference Number: END9298USNP12 / 200859-12 - U.S. Patent Application, Title of Invention "JOINT ARRANGEMENTS FOR MULTI-PLANAR ALIGNMENT AND SUPPORT OF OPERATIONAL DRIVE SHAFTS IN ARTICULATABLE SURGICAL INSTRUMENTS", Agent Reference Number END9298USNP13 / 200859-13, and - U.S. Patent Application, Title of Invention: "SURGICAL INSTRUMENT ARTICULATION JOINT ARRANGEMENTS COMPRISING MULTIPLE MOVING LINKAGE FEATURES", Agent Reference Number: END9298USNP14 / 200859-14.

[0005] The applicant of this application owns the following U.S. patent applications and U.S. patents filed on December 19, 2017, which are incorporated herein by reference in their entirety. - U.S. Patent No. 10,835,330, Title of Invention: "Method for Determining the Position of a Rotatable Jaw of a Surgical Instrument Attachment Assembled" - U.S. Patent No. 10,716,565, Title of Invention: "SURGICAL INSTRUMENTS WITH DUAL ARTICULATION DRIVERS", - U.S. Patent Application No. 15 / 847,325, Title of Invention: "SURGICAL TOOLS CONFIGURED FOR INTERCHANGEABLE USE WITH DIFFERENT CONTROLLER INTERFACES" (currently U.S. Patent Application Publication No. 2019 / 0183491), - U.S. Patent No. 10,729,509, Title of Invention: "SURGICAL INSTRUMENT COMPRISING CLOSURE AND FIRING LOCKING MECHANISM", - U.S. Patent Application No. 15 / 847,315, Title of Invention "ROBOTIC ATTACHMENT COMPRISING EXTERIOR DRIVE ACTUATOR" (currently U.S. Patent Application Publication No. 2019 / 0183594), and - U.S. Design Patent No. D910,847, Title of Invention: "SURGICAL INSTRUMENT ASSEMBLY".

[0006] The applicant of this application owns the following U.S. patent applications and U.S. patents filed on 28 June 2017, which are incorporated herein by reference in their entirety. - U.S. Patent Application No. 15 / 635,693, Title of Invention: "SURGICAL INSTRUMENT COMPRISING AN OFFSET ARTICULATION JOINT" (currently U.S. Patent Application Publication No. 2019 / 0000466), - U.S. Patent Application No. 15 / 635,729, Title of Invention: "SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO" (currently U.S. Patent Application Publication No. 2019 / 0000467), - U.S. Patent Application No. 15 / 635,785, Title of Invention: "SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO" (currently U.S. Patent Application Publication No. 2019 / 0000469), - U.S. Patent Application No. 15 / 635,808, Title of Invention: "SURGICAL INSTRUMENT COMPRISING FIRING MEMBER SUPPORTS" (currently U.S. Patent Application Publication No. 2019 / 0000471), - U.S. Patent Application No. 15 / 635,837, Title of Invention: "SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE TO A FRAME" (currently U.S. Patent Application Publication No. 2019 / 0000472), - U.S. Patent No. 10,779,824, Title of Invention: "SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE BY A CLOSURE SYSTEM", - U.S. Patent Application No. 15 / 636,029, Title of Invention: "SURGICAL INSTRUMENT COMPRISING A SHAFT INCLUDING A HOUSING ARRANGEMENT" (currently U.S. Patent Application Publication No. 2019 / 0000477), - U.S. Patent Application No. 15 / 635,958, Title of Invention: "SURGICAL INSTRUMENT COMPRISING SELECTIVELY ACTUATABLE ROTATABLE COUPLERS" (currently U.S. Patent Application Publication No. 2019 / 0000474), - U.S. Patent Application No. 15 / 635,981, Title of Invention: "SURGICAL STAPLING INSTRUMENTS COMPRISING SHORTENED STAPLE CARTRIDGE NOSES" (currently U.S. Patent Application Publication No. 2019 / 0000475), - U.S. Patent Application No. 15 / 636,009, Title of Invention: "SURGICAL INSTRUMENT COMPRISING A SHAFT INCLUDING A CLOSURE TUBE PROFILE" (currently U.S. Patent Application Publication No. 2019 / 0000476), - U.S. Patent No. 10,765,427, Title of Invention: "METHOD FOR ARTICULATING A SURGICAL INSTRUMENT", - U.S. Patent Application No. 15 / 635,530, Title of Invention: "SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTOR WITH AXIALLY SHORTENED ARTICULATION JOINT CONFIGURATIONS" (currently U.S. Patent Application Publication No. 2019 / 0000457), - U.S. Patent No. 10,588,633, Title of Invention: "SURGICAL INSTRUMENTS WITH OPEN AND CLOSABLE JAWS AND AXIALLY MOVABLE FIRING MEMBER THAT IS INITIALLY PARKED IN CLOSE PROXIMITY TO THE JAWS PRIOR TO FIRING", - U.S. Patent Application No. 15 / 635,559, Title of Invention: "SURGICAL INSTRUMENTS WITH JAWS CONSTRAINED TO PIVOT ABOUT AN AXIS UPON CONTACT WITH A CLOSURE MEMBER THAT IS PARKED IN CLOSE PROXIMITY TO THE PIVOT AXIS" (currently U.S. Patent Application Publication No. 2019 / 0000459), - U.S. Patent No. 10,786,253, Title of Invention: "SURGICAL END EFFECTORS WITH IMPROVED JAW APERTURE ARRANGEMENTS", - U.S. Patent Application No. 15 / 635,594, Title of Invention: "SURGICAL CUTTING AND FASTENING DEVICES WITH PIVOTABLE ANVIL WITH A TISSUE LOCATING ARRANGEMENT IN CLOSE PROXIMITY TO AN ANVIL PIVOT AXIS" (currently U.S. Patent Application Publication No. 2019 / 0000461), - U.S. Patent Application No. 15 / 635,612, Title of Invention: "JAW RETAINER ARRANGEMENT FOR RETAINING A PIVOTABLE SURGICAL INSTRUMENT JAW IN PIVOTABLE RETAINING ENGAGEMENT WITH A SECOND SURGICAL INSTRUMENT JAW" (currently U.S. Patent Application Publication No. 2019 / 0000462), - U.S. Patent No. 10,758,232, Title of Invention: "SURGICAL INSTRUMENT WITH POSITIVE JAW OPENING FEATURES", - U.S. Patent No. 10,639,037, Title of Invention: "SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSURE MEMBER", - U.S. Patent No. 10,695,057, Title of Invention: "SURGICAL INSTRUMENT LOCKOUT ARRANGEMENT", - U.S. Design Patent No. D851,762, Title of Invention "ANVIL", - U.S. Design Patent No. D854,151, Title of Invention "SURGICAL INSTRUMENT SHAFT", and - U.S. Design Patent No. D869,655, Title of Invention: "SURGICAL FASTENER CARTRIDGE".

[0007] The applicant of this application owns the following U.S. patent applications and U.S. patents filed on June 27, 2017, which are incorporated herein by reference in their entirety. - U.S. Patent Application No. 15 / 634,024, Title of Invention: "SURGICAL ANVIL MANUFACTURING METHODS" (currently U.S. Patent Application Publication No. 2018 / 0368839), - U.S. Patent No. 10,772,629, Title of Invention: "SURGICAL ANVIL ARRANGEMENTS", - U.S. Patent Application No. 15 / 634,046, Title of Invention "SURGICAL ANVIL ARRANGEMENTS" (currently U.S. Patent Application Publication No. 2018 / 0368841), - U.S. Patent No. 10,856,869, Title of Invention: "SURGICAL ANVIL ARRANGEMENTS", - U.S. Patent Application No. 15 / 634,068, Title of Invention: "SURGICAL FIRING MEMBER ARRANGEMENTS" (currently U.S. Patent Application Publication No. 2018 / 0368843), - U.S. Patent Application No. 15 / 634,076, Title of Invention: "STAPLE FORMING POCKET ARRANGEMENTS" (currently U.S. Patent Application Publication No. 2018 / 0368844), - U.S. Patent Application No. 15 / 634,090, Title of Invention: "STAPLE FORMING POCKET ARRANGEMENTS" (currently U.S. Patent Application Publication No. 2018 / 0368845), - U.S. Patent Application No. 15 / 634,099, Title of Invention "SURGICAL END EFFECTORS AND ANVILS" (currently U.S. Patent Application Publication No. 2018 / 0368846), and - U.S. Patent No. 10,631,859, Title of Invention: "ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS".

[0008] The applicant of this application owns the following U.S. patent applications filed on June 2, 2020, which are each incorporated herein by reference in their entirety. - U.S. Design Patent Application No. 29 / 736,648, Title of Invention: "STAPLE CARTRIDGE", - U.S. Design Patent Application No. 29 / 736,649, Title of Invention: "STAPLE CARTRIDGE", - U.S. Design Patent Application No. 29 / 736,651, Title of Invention: "STAPLE CARTRIDGE", - U.S. Design Patent Application No. 29 / 736,652, Title of Invention: "STAPLE CARTRIDGE", - U.S. Design Patent Application No. 29 / 736,653, Title of Invention: "STAPLE CARTRIDGE", - U.S. Design Patent Application No. 29 / 736,654, Title of Invention "STAPLE CARTRIDGE", and - U.S. Design Patent Application No. 29 / 736,655, Title of Invention: "STAPLE CARTRIDGE".

[0009] The applicant of this application owns the following U.S. design patent applications and U.S. patents filed on November 14, 2016, which are incorporated herein by reference in their entirety. - U.S. Patent Application No. 15 / 350,621, Title of Invention: "STAPLE FORMING POCKET CONFIGURATIONS FOR CIRCULAR STAPLER ANVIL" (currently U.S. Patent Application Publication No. 2018 / 0132849), - U.S. Patent Application No. 15 / 350,624, Title of Invention: "CIRCULAR SURGICAL STAPLER WITH ANGULARLY ASYMMETRIC DECK FEATURES" (currently U.S. Patent Application Publication No. 2018 / 0132854), - U.S. Design Patent No. D833,608, title "STAPLING HEAD FEATURE FOR SURGICAL STAPLER", and - U.S. Design Patent No. D830,550, titled "SURGICAL STAPLER".

[0010] Numerous specific details are described in order to provide a complete understanding of the overall structure, function, manufacture, and use of the embodiments, as described in the specification and shown in the accompanying drawings. Well-known operations, components, and elements are not described in detail so as not to obscure the embodiments described herein. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and therefore certain structural and functional details disclosed herein may be representative and illustrative. Modifications and changes thereto may be made without departing from the claims.

[0011] The terms “comprise” (and any form of “comprise,” such as “comprises” and “comprising”), “have” (and any form of “have,” such as “has” and “having”), “include” (and any form of “include,” such as “includes” and “including”), and “contain” (and any form of “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, apparatus, or instrument that “comprises,” “has,” “includes,” or “contains” one or more elements has, but is not limited to having only, one or more of those elements. Similarly, an element of a system, apparatus, or machine that "comprises," "has," "includes," or "contains" one or more features has, but is not limited to, one or more of those features.

[0012] The terms “proximal” and “distal” are used herein in reference to the clinician operating the handle portion of the surgical instrument. “Proximal” refers to the part closest to the clinician, and “distal” refers to the part further away from the clinician. For convenience and clarity, spatial terms such as “vertical,” “horizontal,” “up,” and “down” may be used herein in reference to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be restrictive and / or absolute. In the following descriptions, terms such as “first,” “second,” “upper,” “lower,” “up,” and “down” are used for convenience and should not be interpreted as restrictive.

[0013] References to singular items should be understood to include plural items unless explicitly stated otherwise or evident from the text, and vice versa. Grammatical conjunctions, unless otherwise stated or evident from the context, are intended to express any and all disjunctive and conjunctive combinations of joined clauses, sentences, words, etc. Therefore, the term "or" should generally be understood to mean "and / or," etc.

[0014] The descriptions of value ranges in this invention are intended to refer individually, rather than limiting, to any and all values ​​within that range, unless otherwise specified herein, and each distinct value within such range is incorporated into the specification as if it were individually enumerated herein. When accompanied by numerical values, words such as "about" and "approximately" should be interpreted as indicating a deviation that would be understood by a person skilled in the art to function satisfactorily for the intended purpose. Similarly, when used in relation to physical properties, approximate words such as "approximately" or "substantially" should be interpreted as inducing a range of deviation that would be understood by a person skilled in the art to function satisfactorily for the corresponding use, function, purpose, etc.

[0015] Any and all examples provided herein, i.e., the use of illustrative language ("for example," "etc.," or otherwise) is intended solely to better illustrate each embodiment and not to limit the scope of the embodiments. Nothing in the specification should be construed as indicating that any unclaimed element is essential to the practice of the embodiments.

[0016] Various representative devices and methods for performing laparoscopic and minimally invasive surgical procedures are provided. However, it will be readily apparent to the reader that the various methods and devices disclosed herein can be used in many surgical procedures and applications, including, for example, those related to incisional surgical procedures. By reading further into the “Modes for Carrying Out the Invention” section of this specification, the reader will further understand that the various surgical devices disclosed herein can be inserted into the body in any way, for example, through a pre-existing opening, through an incision or puncture hole formed in the tissue, etc. The working portion or end-effector portion of the surgical device may be inserted directly into the patient’s body, or may be inserted via an access device having a working passage through which the end-effector and elongated shaft of the surgical instrument can be advanced.

[0017] A surgical stapling system may comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw, although other embodiments are conceivable in which the staple cartridge is not removable from the first jaw, or at least not easily replaceable from the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closing axis, although other embodiments are conceivable in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to rotate, i.e., articulate, the end effector relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments that do not include articulated joints are also conceivable.

[0018] A staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal and distal ends. During use, the staple cartridge is positioned on the first side of the tissue to be stapled, and the anvil is positioned on the second side of the tissue to be stapled. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Staples, which are then removably housed within the cartridge body, can be deployed into the tissue. The cartridge body includes staple cavities defined within it, and staples are removably housed within the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on the first side of the longitudinal slots, and three rows of staple cavities are positioned on the second side of the longitudinal slots. Other configurations of staple cavities and staples can also be conceived.

[0019] The staples are supported by a staple driver within the cartridge body. The driver is movable between a first, i.e., unfired position and a second, i.e., fired position, to eject the staples from the staple cavity. The driver is held within the cartridge body by a retainer extending around the lower perimeter of the cartridge body and includes an elastic member configured to grip the cartridge body and hold the retainer relative to the cartridge body. The drivers are movable between their unfired and fired positions by a thread. The thread is movable between a proximal position near the proximal end of the cartridge body and a distal position near the distal end of the cartridge body. The thread includes a plurality of inclined surfaces configured to slide beneath the driver and lift the driver, on which the staples are supported and directed toward the anvil.

[0020] In addition to the above, the thread is moved distally by the launching member. The launching member is configured to contact the thread and push it toward its distal end. A longitudinal slot defined within the cartridge body is configured to receive the launching member. The anvil also includes a slot configured to receive the launching member. The launching member further comprises a first cam that engages with a first jaw and a second cam that engages with a second jaw. As the launching member is advanced distally, the first and second cams can control the distance between the deck of the staple cartridge and the anvil, i.e., the inter-tissue gap. The launching member also includes a knife configured to excise tissue trapped between the staple cartridge and the anvil. It is desirable that the knife be positioned at least partially proximal to the inclined surface so that the staple is ejected into the tissue before the knife crosses the tissue.

[0021] Figures 1 to 8 show a surgical stapling device 10 configured to clamp, staple, and cut patient tissue. The surgical stapling device 10 comprises a handle 20, a shaft assembly 100 attached to the handle 20, and an end effector 200. For cutting and stapling patient tissue, the end effector 200 comprises a cartridge jaw 201 and an anvil jaw 203. The anvil jaw 203 is pivotable relative to the cartridge jaw 203 to clamp tissue between the anvil jaw 203 and the cartridge jaw 203. Once tissue is clamped between the jaws 201 and 203, the surgical stapling device 10 may be actuated to advance a launching member through the jaws 201 and 203 to staple and cut the tissue using the end effector 200, as will be discussed in more detail below.

[0022] As will be discussed in more detail below, the end effector 200 is articulated by the articulation range 110 of the shaft assembly 100. Such articulation provides the user of the surgical staple fastener 10 with the ability to position and / or manipulate the end effector 200 more precisely near the target tissue.

[0023] The handle 20 comprises a housing 21 configured to house various mechanical and electrical components, and a handle portion 22 extending from the housing 21. The handle portion 22 is configured to fit in the palm of the user's hand and / or to be grasped and / or held by the user using the surgical stapling device 10. The handle 20 further comprises various actuators and / or triggers configured to be actuated by the user to operate one or more functions of the surgical stapling device 10. The handle 20 comprises a closing trigger 24, a firing trigger 25, and at least one articulated actuator 26. The closing trigger 24 is configured, when actuated by the user, to clamp tissue at the end effector 200 by moving the anvil jaw portion 203 toward the cartridge jaw portion 201. The firing trigger 25 is configured, when actuated by the user, to cut and staple tissue at the end effector 200 by advancing a firing member to eject a staple and cutting the tissue with a knife. The joint motion actuator 26 is configured to articulate the end effector 200 relative to the shaft assembly 100 by the joint motion area 110 when activated by the user. The trigger and actuator of the surgical staple fastener 10 can either trigger one or more motors in the handle 20 to activate various functions of the surgical staple fastener 10, or / or manually drive various drive shafts and components to activate various functions of the surgical staple fastener 10.

[0024] The handle 20 further comprises a nozzle assembly 30 configured to support the shaft assembly 100 inside it. The nozzle assembly 30 includes an actuation wheel 31 configured to be rotated by the user to rotate the shaft assembly 100 and the end effector 200 around the longitudinal axis LA relative to the handle 20. Such a mechanism allows the user of the surgical staple fastener 10 to rotate only the shaft assembly 100 and / or the end effector 200 without having to rotate the entire handle 20.

[0025] The handle 20 further comprises a battery 23 configured to power various electronic components, sensors, and / or motors of the surgical stapling device 10. Embodiments in which the surgical stapling device 10 is directly connected to a power source are also conceivable. Embodiments in which the surgical stapling device 10 is, for example, entirely manual or non-electric are also conceivable. Embodiments in which the articulation of the end effector, clamping and unclamping of the jaw, firing of the end effector staples and cutting of tissue, and rotation of the shaft and / or end effector are all electrically operated systems are also conceivable.

[0026] In at least one case, the shaft assembly 100 and the end effector 200 may be modular and detachable from the handle 20. In at least one case, the end effector 200 may be modular in that it may be detached from the shaft assembly 100 and replaced with a different end effector. In at least one case, the shaft assembly 100 and / or the end effector 200 are usable in a surgical robotic environment. Such embodiments provide power input from a surgical robotic interface to operate each function of the end effector 200. Examples of such surgical robots and surgical tools are further described in U.S. Patent Application Publication No. 2020 / 0138534, titled “ROBOTIC SURGICAL SYSTEM,” published on May 7, 2020, which is incorporated herein by reference in its entirety.

[0027] In at least one case, the shaft assembly 100 and the end effector 200 are configured for use with a surgical robot. In such a case, the shaft assembly 100 and the end effector 200 are configured to be coupled to a surgical robot having multiple output drives. The multiple output drives of the surgical robot are configured to mate with the drive systems of the shaft assembly 100 and the end effector 200. In such a case, the surgical robot can actuate various different functions of the end effector 200, for example, by articulating the end effector around multiple different articulated joints, by rotating the shaft assembly 100 and / or the end effector 200 around their longitudinal axes, by clamping the end effector 200 to clamp tissue between the jaws of the end effector 200, and / or by launching the end effector 200 to cut and / or staple tissue.

[0028] The shaft assembly 100 is configured to house various drive system components and / or electronic components of the surgical staple fastener 10 so that the end effector 200 and the shaft assembly 100 can be inserted through a trocar for laparoscopic surgery. The various drive system components are configured to be actuated by various triggers and actuators of the handle 20. Such components may include a drive shaft for articular movement, a drive shaft for clamping and unclamping the end effector 200, and / or a drive shaft for firing the end effector 200. Such drive shafts may be rotated by a drive system or surgical robotic interface within the handle 20 when the shaft assembly 100 is connected to the handle 20. In various embodiments, the staple fastener end effector may include two independently rotatable drive members, for example, one for grasping tissue and one for firing staples. The staple fastener end effector may further include an articular joint, through which rotational movement may be transmitted. In various embodiments, a stapled end effector may include one or more 3D printed assemblies that can be incorporated into a joint motion system, a gripping system, or a launching system.

[0029] Such a drive shaft may be actuated by a drive system or surgical robotic interface within the handle 20 when the shaft assembly 100 is connected to the handle 20. Such a drive shaft may include linear action, rotational action, or a combination thereof. A combination of rotational and linear action may, for example, use a series of rack gears and / or drive screws.

[0030] In at least one case, the shaft assembly 100 is also configured to accommodate, for example, wires for various sensors and / or motors, which are located within the shaft assembly 100 and / or end effector 200.

[0031] The shaft assembly 100 includes an outer shaft 101 extending from the nozzle assembly 30 to an articulation region 110, which has a double articulated joint, as will be discussed in more detail below. The articulation region 110 allows the end effector 200 to articulate with respect to the outer shaft 101 in two separate planes around two separate axes AA1 and AA2.

[0032] Referring primarily to Figure 4, the articular motion of the end effector 200 is described here. The articular motion region 110 comprises two separate articular joints and two articular actuators 150, 160. This allows the end effector 200 to articulate independently of each other in two different planes around two different axes AA1, AA2. The articular motion region 110 comprises a proximal joint shaft component 120, an intermediate joint shaft component 130, and a distal joint shaft component 140. The proximal joint shaft component 120 is attached to the distal end of the shaft assembly 100, the intermediate joint shaft component 130 is pivotably connected to the proximal joint shaft component 120 and the distal joint shaft component 140, and the distal joint shaft component 140 is fixedly attached to the end effector 200 by a retaining ring 146. As will be discussed in more detail below, this configuration provides articulation of the end effector 200 relative to the shaft assembly 100 around axes AA1 and AA2, independently of each other.

[0033] The proximal joint shaft component 120 comprises a proximal annular portion 121 fixedly fitted within the outer shaft 101. The proximal joint shaft component 120 also includes a hollow passage 122, which allows various drive system components to pass through it, and further includes an articulation tab 123 having a pinhole 124 configured to receive an articulation pin 125. The articulation pin 125 pivotably connects the proximal joint shaft component 120 to the proximal articulation tab 131 of the intermediate joint shaft component 130. To articulate the end effector 200 around axis AA1, the articulation actuator 150 is actuated linearly in either the distal or proximal direction. Such an actuator may comprise a bar or rod made of any suitable material, such as metal and / or plastic. The articulation actuator 150 is pivotably mounted on the articulation bridging portion 151. The joint motion bridging portion 151 is pivotably attached to the intermediate joint shaft component 130 out of axis relative to the joint connection pin 125, so that when the joint motion actuator 150 is actuated, the joint motion bridging portion 151 applies torque to the intermediate joint shaft component 130 out of axis relative to the joint connection pin 125, causing the intermediate joint shaft component 130, and thus the end effector 200, to pivot around axis AA1 relative to the proximal joint shaft component 120.

[0034] The intermediate joint shaft component 130 is pivotably connected to the proximal joint shaft component 120 by an articulation pin 125 defining axis AA1. Specifically, the intermediate joint shaft component 130 includes a proximal articulation tab 131 pivotably connected to the proximal joint shaft component 120 by the articulation pin 125. The intermediate joint shaft component 130 further includes a hollow passage 132 configured to allow various drive system components to pass through it, and a distal articulation tab 133. The distal articulation tab 133 includes a pin hole 134 configured to receive another articulation pin 136 defining axis AA2, and a key 135 projecting distally.

[0035] To articulate the end effector 200 around axis AA2, the articulation cable 160 is actuated by a key 135 to apply articulation torque to the proximal tab 141 of the distal joint shaft component 140. The articulation cable 160 is fixed to a key 135 such that the key 135 pivots relative to the intermediate joint shaft component 130 when the cable 160 is rotated. The key 135 is fitted into a keyhole 144 of the distal joint shaft component 140. Note that the key 135 is not fixed to the intermediate joint shaft component 130 and can rotate relative to the intermediate joint shaft component 130. The articulation cable 160 also contacts the proximal tab 141 around a pinhole 142. This provides additional torque motion from the articulation cable 160 to the distal joint shaft component 140. The joint pin 136 is received in the pin hole 142 and pivotably connects the intermediate joint shaft component 130 and the distal joint shaft component 140.

[0036] In at least one case, the articular movement cable 160 can be pulled only in the proximal direction. In such a case, only one side of the articular movement cable 160 is pulled in the proximal direction, causing the end effector 200 to articulate in the desired direction. In at least one case, the articular movement cable 160 is opposedly pushed and pulled. In other words, the cable 160 may include a rigid structure such that one side of the articular movement cable 160 is pushed distally, while the other side is pulled proximal. Such a configuration may allow the articular movement force to be divided between the pushed half and the pulled half of the cable 160. In at least one case, the push-pull configuration allows a larger articular movement force to be transmitted to the corresponding articular joint. Such a force may be necessary in a configuration having two articular joints. For example, if the proximal joint is fully articulated, more force may be required in the articulation actuator to articulate the distal joint due to the extension and / or lengthening distance that the articulation actuator for the distal joint must travel.

[0037] The distal joint shaft component 140 further includes a cutout 143 that allows various drive components to pass through it. The retaining ring 146 secures the channel 210 of the cartridge jaw 201 to the distal joint shaft component 140, thereby securing the end effector assembly 200 to the distal end of the joint movement area 110.

[0038] As described above, the anvil jaw 201 is movable relative to the cartridge jaw 203 and clamps and unclamps tissue with the end effector 200. The operation of this function of the end effector 200 is described here. The cartridge jaw 201 comprises a channel 210 and a staple cartridge 220 configured to be received in a cavity 214 of the channel 210. The channel 210 further comprises an annular groove 211 configured to receive a retaining ring 146 and a pair of pivot holes 213 configured to receive jaw connecting pins 233. The jaw connecting pins 233 allow the anvil jaw 203 to pivot relative to the cartridge jaw 201.

[0039] The anvil jaw portion 203 comprises an anvil body 230 and a pair of pivot holes 231. The pivot holes 231 in the proximal portion of the anvil jaw portion 203 are configured to receive jaw connecting pins 233, thereby pivotally connecting the anvil jaw portion 203 to the cartridge jaw portion 201. A closing drive unit 250 is provided to open and close the anvil jaw portion 203 relative to the cartridge jaw portion 201.

[0040] The closing drive unit 250 is actuated by a flexible drive section 175 consisting of a universal joint that is positioned or formed with its ends touching. In various cases, the flexible drive section 175 may include a series of 3D printed universal joints that are all printed together as a single continuous system. As will be discussed in more detail below, the flexible drive section 175 is driven by an input shaft that passes through the shaft assembly 100. The flexible drive section 175 transmits rotational operating motion through a double articulated joint. The closing drive unit 250 includes a closing screw 251 and a closing wedge section 255 that is screwably connected to the closing screw 251. The closing wedge section 255 is configured to reliably cam the anvil jaw section 203 to open and close. The closing screw 251 is supported by a first support 258 and a second support 259 fixed within the channel 210.

[0041] To move the anvil jaw 203 between the clamped position (Figure 8) and the released position (Figure 7), the closing drive shaft is actuated to activate the flexible drive section 175. The flexible drive section 175 is configured to rotate a closing screw 251 that displaces the closing wedge 255. For example, the closing wedge 255 is screw-connected to the closing screw 251, and rotational movement of the closing wedge 255 relative to the staple cartridge 220 is suppressed. Depending on the direction in which the closing screw 251 is rotated, the closing wedge 255 is driven proximal or distal.

[0042] To clamp the end effector 200 from the unclamped position (Figure 7), the closing wedge portion 255 is moved proximal. As the closing wedge portion 255 moves proximal, the proximal cam surface 256 of the closing wedge portion 255 contacts the corresponding cam surface 234 defined on the proximal end 235 of the anvil body 230. When the cam surface 256 contacts the cam surface 234, a force is applied to the proximal end 235 of the anvil body 230, rotating the anvil body 230 around the pin 233 to the clamped position (Figure 8).

[0043] To release or unclamp the end effector 200 from the clamped position (Figure 8), the closing wedge portion 255 is moved distally by rotating the closing screw 251 in the opposite direction to the direction in which the closing wedge portion 255 is moved proximal. As the closing wedge portion 255 is moved distally, a pair of nubs 257 extending from the distal end of the closing wedge portion 255 contact the cam surface 234 near the tab 237 that extends downward on the anvil body 230. When the nubs 257 contact the cam surface 234 near the tab 237, a force is applied to the anvil body 230, causing the anvil body 230 to rotate around the pin 233 to the open position (Figure 7).

[0044] In at least one case, the contour of the cam surface 234 corresponds to the contour of the cam surface 256. For example, the cam surfaces 234 and 256 may coincide so that the maximum cam force is applied to the anvil body 230 to cause a desired rotation of the anvil body 230. As shown in Figure 8, for example, the cam surface 234 defined by the proximal end 235 of the anvil body 230 includes an inclined section similar to that of the upper inclined section of the cam surface 256.

[0045] As described above, the surgical stapling device 10 may be operated to advance the launching member through the jaws 201, 203 to staple and cut tissue using the end effector 200. Next, the function of deploying staples 226 from the staple cartridge 220 and cutting tissue with the knife 283 will be described. The staple cartridge 220 comprises a cartridge body 221, a plurality of staple drivers 225, and a plurality of staples 226 detachably stored within the cartridge body 221. The cartridge body 221 comprises a deck surface 222, a plurality of staple cavities 223 arranged in a longitudinal row defined within the cartridge body 221, and a longitudinal slot 224 dividing the cartridge body 221 in two. The knife 283 is driven through the longitudinal slot 224 and configured to cut tissue clamped between the anvil body 230 and the deck surface 221.

[0046] The deck surface 221 includes a tissue support surface that is contoured laterally. In various embodiments, the contour of the deck surface 221 may form a peak along the central portion of the cartridge body 221. Such a peak may cover a longitudinally extending firing screw 261 that extends through the central portion of the cartridge body 221, as further described herein. The increased height along the peak may, in various cases, be associated with smaller tissue gaps along the firing path of the knife 283. In certain embodiments of this disclosure, the driver height, formed staple height, staple pocket extension height, and / or staple overdrive distance may also vary laterally along the deck surface 221. Laterally variable stapling (e.g., a combination of 2D and 3D stapling) has also been conceived and is further described herein.

[0047] The staple driver 225 is configured to be lifted by the thread 280 as the thread 280 is pushed distally through the staple cartridge 220, thereby ejecting the staple 226, supported by the staple driver 225, into the staple cavity 223. The thread 280 includes an inclined portion 281 for contact with the staple driver 225. The thread 280 also includes a knife 283. The thread 280 is configured to be pushed by the launching member 270.

[0048] To deploy staples 226 and cut tissue with a knife 283, the end effector 200 comprises a launch drive unit 260. The launch drive unit 260 is actuated by a flexible drive shaft 176. As will be discussed in more detail below, the flexible drive shaft 176 is driven by an input shaft that passes through a shaft assembly 100. The flexible drive shaft 176 transmits rotational actuation motion through a double-joint motion joint. The launch drive unit 260 comprises a launch screw 261 configured to be rotated by the flexible drive shaft 176. The launch screw 261 comprises a journal supported in a support member 259 and a bearing in a channel 210. In various cases, the launch screw 261 may float relative to the channel 210, as will be further described herein. The launch screw 261 comprises a proximal end 262 supported within the support member 259 and the channel 210, a distal end 263 supported within the channel 210, and threads 265 extending along a portion of the length of the launch screw 261.

[0049] The launching member 270 is screw-connected to the launching screw 261 such that, as the launching screw 261 rotates, the launching member 270 advances distally or retracts proximally along the launching screw 261. Specifically, the launching member 270 comprises a body portion 271 having a defined hollow passage 272 inside. The launching screw 261 is configured to be received within the hollow passage 272 and to be screw-connected to a threaded component 273 of the launching member 270. Therefore, as the launching screw 261 rotates, the threaded component 273 applies a linear force to the body portion 271, causing the launching member 270 to advance distally or retract proximally. When the launching member 270 advances distally, it pushes the thread 280. As further described herein, distal movement of the thread 280 causes the ejection of staples 223 by engaging multiple staple drivers 225. The drivers 225 are triple drivers configured to fire multiple staples 223 simultaneously. The drivers 225 may, in various cases as further described herein, include lateral asymmetry to maximize the width of the thread rail and to house the firing thread 261 below the center of the cartridge 220.

[0050] At some point during the firing of the end effector 200, the user may retract the firing member 270 to allow the jaws 201 and 203 to be released. In at least one case, the firing member 270 must be fully retracted to release the jaws 201 and 203, in which case upper and lower cam members are provided on the main body portion 271 such that they can be disengaged from the jaws 201 and 203 when the firing member 270 is fully retracted.

[0051] In various cases, the launching member 270 may be a hybrid structure of plastic and metal parts, as further described herein. In various cases, the threaded component 273 may be a metal component incorporated into the launching member body 271, for example, by insert molding or overmolding.

[0052] The launching member 270 may also be referred to as an I-beam in certain cases. The launching member 270 may include an intricately 3D printed geometric shape that contains a grid pattern space within it. In various cases, 3D printing allows the launching member or a portion thereof to function as a spring, allowing a portion to bend more easily, thereby improving, for example, the force distribution and / or tolerances during the launch stroke.

[0053] Figures 9 to 11 show a surgical staple assembly 300 comprising a shaft assembly 310 and the end effectors 200 shown in Figures 1 to 8 attached to the shaft assembly 310. The shaft assembly 310 may be similar in many respects to various other shaft assemblies discussed herein. However, the shaft assembly 310 comprises a single articulated joint and an articulated bar configured to articulate the end effector 200 around the single articulated joint. The surgical staple assembly 300 is configured to cut and staple tissue. The surgical staple assembly 300 may be attached to a surgical instrument handle and / or a surgical robotic interface. The surgical instrument handle and / or surgical robotic interface may be configured to actuate various functions of the surgical staple assembly 300. The shaft assembly 310 comprises an articulated joint 320. As will be discussed in more detail below, the end effector 200 is configured to articulate with respect to the outer shaft 311 of the shaft assembly 310 around axis AA.

[0054] The shaft assembly 310 comprises an outer shaft 311, a first shaft coupling component 330, and a second shaft coupling component 350 pivotably connected to the first shaft coupling component 330 by an articulating pin 354. The first shaft coupling component 330 comprises a proximal tube portion 331 configured to fit into the inner diameter of the outer shaft 311. Such fitting may include, for example, press-fitting. However, any preferred mounting means may be used. The first shaft coupling component 330 also includes a distal portion 332. The distal portion 332 comprises an articulating tab 333 having a pinhole 334 defined therein and a hollow passage 335 through which various drive components of the surgical staple fastening assembly 300 can pass. Such drive components may include, for example, an articulating actuator, a closing actuator, and / or a firing actuator.

[0055] The first shaft coupling component 330 is pivotably connected to the second shaft coupling component 350 by an articulation pin 354. The articulation pin 354 is also received in a pinhole 353 of an articulation tab 351 that extends proximal to the second shaft coupling component 350. The pinhole 353 is axially aligned with a pinhole 334. The articulation pin 354 allows the second shaft coupling component 350 to articulate with the first shaft coupling component 330 around the articular motion axis AA. The second shaft coupling component 350 further comprises a pin projection 352 extending from the proximal-extending articulation tab 351. As will be discussed in more detail below, the pin projection 352 is configured to be pivotably connected to the articular motion drive system. The second shaft coupling component 350 further comprises a distal portion 355 having an annular groove 356 configured to receive a retaining ring 358. The distal portion 355 also includes a hollow passage 357 through which various drive components of the surgical staple fastening assembly 300 can pass. The retaining ring 358 is configured to hold the first jaw portion 201 to the second shaft coupling component 350 by fitting into the annular groove 211 of the cartridge channel 210 and the annular groove 356 of the second shaft coupling component 350.

[0056] An articular bar 360 is provided to articulate the end effector 200 around the articular axis AA. The articular bar 360 may be actuated by any preferred means, such as a robot or an electric input and / or a manual handle trigger. The articular bar 360 may be actuated, for example, in the proximal and distal directions. Embodiments are also conceivable in which the articular motion system includes rotational drive action in addition to, or instead of, linear action. The articular bar 360 extends through an outer shaft 311. The articular bar 360 has a distal end 361 pivotably connected to an articular connector 362. The articular connector 362 is pivotably connected from an articular tab 351 extending in the proximal direction to a pin projection 352 extending eccentrically with respect to the articular axis AA. Such eccentric connection of the articular joint 362 allows the articular bar 360 to apply force to the second joint shaft component 350, thereby rotating the second shaft joint component 350, and thus the end effector 200, relative to the first joint shaft component 330. The articular bar 360 can advance distally to rotate the end effector 200 in a first direction around the articular motion axis AA, or retract proximal to rotate the end effector 200 in a second direction opposite to the first direction around the articular motion axis AA.

[0057] The shaft assembly 310 further comprises a joint component support structure 340 positioned within the joint joint 320. Such a support structure can provide support to various drive components configured to reach the end effector 200 through the joint joint 320 when the end effector 200 is articulated. The support structure 340 may also serve to isolate the drive components from tissue residue during use.

[0058] Figures 12–14 show a surgical staple assembly 400 comprising a shaft assembly 410 and the end effectors 200 shown in Figures 1–8 attached to the shaft assembly 410. The shaft assembly 410 may be similar in many respects to various other shaft assemblies discussed herein. However, the shaft assembly 410 comprises a single articulated joint and an articulated cable configured to articulate the end effector 200 around the single articulated joint. The surgical staple assembly 400 is configured to cut and staple tissue. The surgical staple assembly 400 may be attached to a surgical instrument handle and / or a surgical robotic interface. The surgical instrument handle and / or surgical robotic interface may be configured to actuate various functions of the surgical staple assembly 400. The shaft assembly 410 comprises an articulated joint 420. As will be discussed in more detail below, the end effector 200 is configured to articulate with respect to the outer shaft 411 of the shaft assembly 310 around axis AA.

[0059] The shaft assembly 410 comprises an outer shaft 411, a first shaft coupling component 430, and a second shaft coupling component 450 pivotably connected to the first shaft coupling component 430 by an articulating pin 454. The first shaft coupling component 430 comprises a proximal tube portion 431 configured to fit into the inner diameter of the outer shaft 411. Such fitting may include, for example, press-fitting. However, any preferred mounting means may be used. The first shaft coupling component 430 also includes a distal portion 432, which comprises an articulating tab 433 having a pinhole 434 defined therein. The distal portion 432 further defines a hollow passage 435 through which various drive components of the surgical staple fastening assembly 400 can pass. Such drive components may include, for example, articulating actuators, closing actuators, and / or firing actuators.

[0060] The first shaft coupling component 430 is pivotably connected to the second shaft coupling component 450 by an articulation pin 454. The articulation pin 454 is also received in a pinhole 453 of an articulation tab 451 extending proximal to the second shaft coupling component 450. The articulation pin 454 enables the second shaft coupling component 450 to articulate with the first shaft coupling component 430 around the articular axis AA. The second shaft coupling component 450 further comprises a drive ring structure 452. The drive ring structure 452 extends from the proximal articulation tab 451 and further defines a portion of the pinhole 453. As will be discussed in more detail below, the drive ring structure 452 is configured to be engaged by an articular drive system. The second shaft coupling component 450 further comprises a distal portion 455 having an annular groove 456 configured to receive a retaining ring 458. A hollow passage 457 passing through the distal portion 455 is configured to receive various drive components of the surgical staple fastening assembly 400 through it. A retaining ring 458 is configured to hold the first jaw portion 201 to the second shaft coupling component 450 by fitting into the annular groove 211 of the cartridge channel 210 and the annular groove 456 of the second shaft coupling component 450.

[0061] An articular motion cable 460 is provided to articulate the end effector 200 around the articular motion axis AA. The articular motion cable 460 may be actuated by any preferred means, such as a robotic input on the handle of a handheld surgical instrument and / or a manual trigger. The articular motion cable 460 may have an antagonistic actuation profile. In other words, when the first side of the articular motion cable 460 is pulled proximal, the second side of the articular motion cable 460 is able to advance distally, like a pulley system. Similarly, when the second side is pulled proximal, the first side is able to advance distally. The articular motion cable 460 extends through the outer shaft 411. The articular motion cable 460 is positioned around a drive ring structure 452 and held thereon by friction, allowing rotation of the second shaft coupling component 450 when the articular motion cable 460 is actuated. When the articular motion cable 460 is actuated, it is configured to apply rotational torque to the drive ring structure 452 of the second joint shaft component 450, and thus to the end effector 200. Such torque is configured to rotate or pivot the second joint shaft component 450 relative to the first joint shaft component 430, thereby articulating the end effector 200 relative to the outer shaft 411. The first side of the articular motion cable 460 can pull the end effector 200 to rotate in a first direction around the articular motion axis AA, and the second side of the articular motion cable 460 can pull the end effector 200 to rotate in a second direction opposite to the first direction around the articular motion axis AA.

[0062] The shaft assembly 410 further comprises a joint component support structure 440 positioned within the joint joint 420. Such a support structure 440 can provide support to various drive components configured to reach the end effector 200 through the joint joint 420 when the end effector 200 is articulated. The support structure 440 may also serve to isolate the drive components from tissue residue during use.

[0063] The surgical staple assembly 400 further comprises a closing drive shaft section 475 and a launch drive shaft section 476, each configured to transmit rotational motion to the end effector 200 through an articulated joint 420. The drive shaft sections 475 and 476 are configured to passively expand and contract longitudinally when the end effector 200 is articulated. For example, articulation may cause expansion and contraction of the drive shaft sections 475 and 476 to correspond to the respective longitudinal extension or contraction of the drive shaft length resulting from the articulation of the end effector 200 relative to the shaft assembly 410. During expansion and contraction of the drive shaft sections 475 and 476, they maintain rotational drive engagement with the corresponding input shaft and output shaft within the end effector 200, which extend through the outer shaft 411. In at least one case, the output shaft comprises a closing screw 251 configured to result in gripping, closing, or tissue manipulation by the jaws 201, 203, and a launching screw 261 configured to result in clamping of the jaws 201, 203 and launching of the launching member 270.

[0064] Figures 15–17 show a surgical staple assembly 500 comprising a shaft assembly 510 and the end effectors 200 shown in Figures 1–8 attached to the shaft assembly 510. The shaft assembly 510 may be similar in many respects to various other shaft assemblies discussed herein. However, the shaft assembly 510 comprises a single articulated joint and drive shaft section configured to passively expand and contract. The surgical staple assembly 500 is configured to cut and staple tissue. The surgical staple assembly 500 may be attached to a surgical instrument handle and / or a surgical robotic interface. The surgical instrument handle and / or surgical robotic interface may be configured to actuate various functions of the surgical staple assembly 500. The shaft assembly 510 comprises an articulated joint 520. As will be discussed in more detail below, the end effector 200 is configured to articulate around axis AA.

[0065] The shaft assembly 510 comprises a first shaft coupling component 530 and a second shaft coupling component 540 pivotably connected to the first shaft coupling component 530 by an articulating pin 543. The first shaft coupling component 530 is configured to be attached to the shaft of a surgical instrument assembly and / or a surgical robotic interface. The first shaft coupling component 530 comprises a proximal portion 531 and an articulating tab 533 having a pinhole 534 defined therein. In at least one case, the first shaft coupling component 530 includes a hollow passage through which various drive components of the surgical staple fastening assembly 400 can pass. Such drive components may include, for example, articulating actuators, closing actuators, and / or firing actuators.

[0066] The first shaft coupling component 530 is pivotably connected to the second shaft coupling component 540 by an articulation pin 543. The articulation pin 543 is also received in a pinhole 542 of an articulation tab 541 extending proximal to the second shaft coupling component 540. The articulation pin 543 allows the second shaft coupling component 540 to articulate with respect to the first shaft coupling component 530 around the articular axis AA. The second shaft coupling component 540 further comprises a distal portion 545 having an annular groove 547 configured to receive a retaining ring 548 and a hollow passage 546 through which various drive components of the surgical staple fastening assembly 500 can pass. The retaining ring 548 is configured to hold the first jaw portion 201 to the second shaft coupling component 540 by fitting into the annular groove 211 of the cartridge channel 210 and the annular groove 547 of the second shaft coupling component 540.

[0067] The end effector 200 can be articulated around axis AA using any suitable articulation drive system. In at least one case, the end effector 200 is articulated passively. In such a case, the end effector 200 may be pressed against tissue, for example, to apply a force to the end effector 200 to cause it to articulate around the articulation axis. In at least one case, the end effector 200 further comprises a spring configured to apply a neutral biasing force to a second shaft joint section 540, for example, to bias the end effector 200 toward a non-articulation configuration.

[0068] The surgical staple fastening assembly 500 further comprises a closing drive shaft segment 575 and a launch drive shaft segment 576, each configured to transmit rotational motion to the end effector 200 through an articulated joint 520. The drive shaft segments 575 and 576 are configured to passively expand and contract longitudinally when the end effector 200 is articulated. The articulation expands and contracts the drive shaft segments 575 and 576 to correspond to the longitudinal extension or contraction of the drive shaft length resulting from the articulation of the end effector 200. During the expansion and contraction of the drive shaft segments 575 and 576, they maintain rotational drive engagement with the corresponding input and output shafts within the end effector 200. In at least one case, the output shaft comprises a closing screw 251 and a launch screw 261, which are further described herein.

[0069] Figures 18–20 show a surgical staple-fastening end-effector assembly 600 comprising a shaft portion 610 and an end effector 600. The end effector assembly 600 is similar in many respects to various other end effector assemblies disclosed herein, except that it comprises a multi-component launching member driven by a flexible launching shaft. The end effector assembly 600 is configured to cut and staple tissue. The end effector assembly 600 may be attached to a surgical instrument handle and / or a surgical robotic interface by a proximal tab 611 of the shaft portion 610. The surgical instrument handle and / or surgical robotic interface may be configured to actuate various functions of the end effector assembly 600. The end effector assembly 600 comprises a cartridge channel jaw 620 and an anvil jaw 660 pivotably attached to the cartridge channel jaw 620, and clamps tissue between the cartridge channel jaw 620 and the anvil jaw 660.

[0070] The cartridge channel jaw 620 comprises a channel 630 including a proximal end 631, a staple cartridge 640 configured to house a plurality of staples and to be received within the channel 630, and a support brace 650 fitted into the staple cartridge 640. The staple cartridge 640 and the support brace 650 are configured to be assembled together before the staple cartridge 640 is placed within the channel 630. As will be discussed in more detail below, the support brace 650 is configured to further support the launcher assembly as it is advanced through the end effector assembly 600.

[0071] The anvil jaw 660 is configured to form staples ejected from the staple cartridge 640. The anvil jaw 660 has a proximal end 661 having a pair of pinholes 662 defined inside, configured to receive a connecting pin 663. The anvil jaw 660 is pivotable around the connecting pin 663 between an unclamped position and a fully clamped position. The connecting pin 663 is also received in a pair of pinholes 633 defined in the proximal end 631 of the channel 630. The connecting pin 663 serves to pivotally attach the anvil jaw 660 to the channel 630. In at least one case, the channel 630 is attached to the shaft portion 610 by a retaining ring or band that fits around an annular groove 632 of the channel 630 and an annular groove 615 of the shaft portion 610. The retaining ring or band is configured to hold the channel 630 to the shaft portion 610.

[0072] The end effector assembly 600 includes a closing drive unit 670 configured to grasp tissue between the anvil jaw 660 and the cartridge channel jaw 620 by pivoting the anvil jaw 660 relative to the channel 630. The end effector assembly 600 also includes a firing drive unit 680 configured to clamp, staple, and cut tissue by deploying a plurality of staples from a staple cartridge 640. The closing drive unit 670 includes a closing screw 671 positioned within the channel 630 and a closing wedge 675 screwably connected to the closing screw 671. As the closing screw 671 is rotated, the closing wedge 675 is advanced distally or retracted proximally to open or close the anvil jaw 660, respectively. The closing drive unit 670 may be actuated by any preferred means. For example, the rotary drive shaft may extend from the operating interface through the shaft portion 610 to rotate, for example, a closing screw 671. Other preferred embodiments of the rotary drive shaft are further described herein.

[0073] The launch drive unit 680 includes a flexible drive shaft 681 configured to move linearly through the end effector assembly 600. The flexible drive shaft 681 may be actuated, for example, by a manually actuated drive shaft of a robot input and / or handle assembly. The flexible drive shaft 681 is configured to extend through a hollow passage 614 of the distal end 613 of the shaft portion 610, and the end effector assembly 600 is flexible so that it can articulate with respect to the shaft from which the end effector 600 extends. The flexible drive shaft 681 extends through a clearance slot 676 defined within the closing wedge portion 675 and is fixedly mounted to the lower launch member 682. The lower launch member 682 is configured to be reused with different staple cartridges.

[0074] The staple cartridge 640 includes a disposable upper launching member 683 configured to hook into or latch onto the lower launching member 682 so that the lower launching member 582 can push or drive the upper launching member 683 through the staple cartridge 640 and the support brace portion 650. In other words, the firing action includes a two-part launching member, consisting of a disposable upper launching member 683 incorporated into the cartridge 640 and a reusable lower launching member 682 incorporated into the firing drive unit 680, which can be connected to each other when the cartridge 640 is seated in the elongated channel 630. The two-part launching member is described further herein.

[0075] The upper launching member 683 comprises an upper flange configured to engage and position with the anvil jaw 660, a knife blade configured to cut tissue, and a latch portion configured to hook-engage with the lower launching member 682. The staple cartridge 640 further comprises a thread 684 configured to engage with a staple driver positioned within the staple cartridge 640 to eject staples from the staple cartridge 640. Because the knife and blade are incorporated into the disposable upper launching member 683 of the staple cartridge 640, new blades and / or unused blades can be supplied with each staple cartridge loaded into the end effector assembly 600.

[0076] The lower firing member 682 and the upper firing member 683 are configured to move through a support brace 650, thereby configuring vertical loading related to the firing sequence to be distributed through the support brace 650, the staple cartridge 640, the channel 630, and the anvil jaw 660. The support brace 650 may be made of, for example, a metallic material inserted into the staple cartridge 640. The support brace 650 includes a key rail 655 configured to fit into a corresponding key slot defined within the longitudinal slot of the staple cartridge 640. The support brace 650 further includes a longitudinal slot 653 configured to receive the knife of the upper firing member 683, and a cylindrical passage 657 configured to receive a portion of the upper firing member 683, a portion of the lower firing member 682, and a flexible drive shaft 681. The support brace 650 further includes a vertical key extension 656 configured to be received into a corresponding key hole in the cartridge deck. Such extensions can be seen through the cartridge deck when the support brace portion 650 is installed inside the staple cartridge 640. In at least one case, the support brace portion 650 is configured to be inserted into the staple cartridge 640 from the bottom of the staple cartridge 640 facing the channel 630.

[0077] The support brace section 650 further comprises a proximal tab 651 and a distal tab 653, both configured to engage with the channel 630. The tabs 651 and 653 are configured to distribute at least a portion of the force transmitted through the assembly 600 by the launch drive unit 680 and its corresponding components. The distal tab 651 may serve to prevent the upper launch member 683 and the lower launch member 682 from being pushed through the distal end of the support brace section 650 by sharing and / or redistributing the load applied to the support brace section 650 by the launch drive unit 680 with the channel 630.

[0078] If the staple cartridge 640 is replaced so that the end effector assembly 600 can be reused, the staple cartridge 640 is removed from the channel jaw 630. When the staple cartridge 640 is removed from the channel jaw 630, the upper firing member 683, thread 684, support brace 650, and staple cartridge 640 are removed. A replacement staple cartridge may be provided in a new knife.

[0079] Various embodiments disclosed herein may be used in connection with a robotic system 700. For example, a typical robotic system is depicted in Figures 21 to 23. Figure 21 depicts a master controller 701 which may be used in connection with a surgical robot, such as the robotic arm-slave cart 800 depicted in Figure 22. The master controller 701 and the robotic arm-slave cart 800, as well as their individual components and control systems, are collectively referred to herein as the robotic system 700. Examples of such systems and apparatus are disclosed in U.S. Patent No. 7,524,320, titled "MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTIC SURGICAL TOOLS," and U.S. Patent No. 9,072,535, titled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," which are incorporated herein by reference in their entirety. As is well known, the master controller 701 typically includes a controller (commonly represented as 703 in Figure 21) that the surgeon grasps and manipulates in space while viewing the surgery via a stereo display 702. The controller 701 generally includes a manual input device, which often further includes an operable handle, trigger, or actuator that moves preferably in multiple degrees of freedom and operates the tool (e.g., closing the grasping jaw, applying an electric potential to an electrode, etc.).

[0080] As shown in Figure 22, in one embodiment, the robotic arm cart 800 may be configured to operate one or more surgical tools, generally indicated as 900. Various robotic surgical systems and methods utilizing the configuration of a master controller and a robotic arm cart are disclosed in U.S. Patent No. 6,132,368, titled "MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD," the entirety of which disclosure is incorporated herein by reference.

[0081] In various embodiments, the robotic arm cart 800 has a base 702, from which a surgical tool 900 may be supported in the illustrated embodiment. In various embodiments, the surgical tool(s) 900 may be supported by a series of manually articulated linkage mechanisms, commonly referred to as a setup joint 804 and a robotic manipulator 806. In various embodiments, the linkage mechanisms and joint configurations can facilitate the rotation of the surgical tool around a point in space, as further and in full described in U.S. Patent No. 5,817,084, titled “REMOTE CENTER POSITIONING DEVICE WITH FLEXIBLE DRIVE,” the entire disclosure of which is incorporated herein by reference. This parallelogram configuration restricts the rotation to a pivotal motion around an axis 812a, sometimes referred to as the pitch axis. The connecting portion supporting the parallelogram linkage mechanism is pivotally mounted to the setup joint 804 (Figure 22), so that the surgical tool can further rotate about axis 812b, also called the yaw axis. The pitch axis 812a and the yaw axis 812b intersect at the remote center 814, which is aligned along the elongated shaft of the surgical tool 900. The surgical tool 900 may have further driven degrees of freedom supported by the manipulator 806, including the sliding motion of the surgical tool 900 along the longitudinal axis "LT-LT". As the surgical tool 900 slides relative to the manipulator 806 along the axis LT-LT of the tool (arrow 812c), the remote center 814 remains immobile relative to the base 816 of the manipulator 806. Therefore, the entire manipulator is generally moved to reposition the remote center 814. The linkage mechanism 808 of the manipulator 806 may be driven by a series of motors 820. These motors actively move the linkage mechanism 808 in response to commands from the control system's processor. Motor 820 may also be used to operate the surgical tool 900. Alternative joint structures and setup configurations can also be conceived.Examples of other fittings and setup configurations are disclosed, for example, in U.S. Patent No. 5,878,193, titled "AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING," the entirety of which is incorporated herein by reference.

[0082] While data communication between robotic components and the processor of a robotic surgical system is described herein primarily in relation to communication between surgical tools and the master controller 701, it should be understood that similar communication may also occur between circuits such as manipulators, setup fittings, endoscopes, or other image acquisition devices and the processor of the robotic surgical system for purposes such as component suitability assessment, component type identification, component calibration (offset, etc.), and confirmation of the component's connection to the robotic surgical system. In at least one embodiment, the various surgical instruments disclosed herein may be used in conjunction with other robotic control or automated surgical systems and are not necessarily limited to use with the specific robotic system components shown in Figures 21-23, as described in the aforementioned references.

[0083] During various laparoscopic surgical procedures, it is a common technique to access the surgical site located within the patient's abdomen by inserting the surgical end-effector portion of a surgical instrument through a trocar placed in the patient's abdominal wall. In its simplest form, the trocar is a pen-shaped instrument with a sharp triangular tip on one end, typically used in a hollow tube known as a cannula or sleeve, through which the surgical end-effector may be introduced. Such an instrument forms an access port in the body cavity into which the surgical end-effector can be inserted. The inner diameter of the trocar's cannula inevitably limits the size of the end-effector and drive support shaft of the surgical instrument that can be inserted through the trocar.

[0084] Regardless of the specific type of surgical procedure being performed, once a surgical end-effector is inserted into the patient through a trocar cannula, it is often necessary to move the surgical end-effector relative to the shaft assembly positioned within the trocar cannula in order to properly position it relative to the tissue or organ being treated. This movement or positioning of the surgical end-effector relative to the portion of the shaft that remains within the trocar cannula is often referred to as "articular movement" of the surgical end-effector. To facilitate such articular movement of the surgical end-effector, various articular joints have been developed for attaching the surgical end-effector to the associated shaft. As is expected in many surgical procedures, it is desirable to use a surgical end-effector with the largest possible range of articular movement.

[0085] Due to the size limitations imposed by the size of the trocar cannula, the components of the articular movement joint must be sized to be freely insertable through the trocar cannula. These size limitations also restrict the size and configuration of various drive members and components that operably interact with motors and / or other control systems supported within a housing, which may be handheld or part of a larger automated system. Often, these drive members must operably pass through the articular movement joint to be operably coupled to or operably interacted with the surgical end effector. For example, one such drive member is commonly used to impart joint control movement to a surgical end effector. During use, the articular movement drive member may be deactivated to position the surgical end effector in a non-articular movement position to facilitate insertion of the surgical end effector through the trocar, and then activated to articularize the surgical end effector to the desired position once it is in the patient's eye.

[0086] Therefore, the aforementioned size limitations present many challenges in developing articular motion systems that can achieve the desired range of joint movement and accommodate the various different drive systems necessary to operate the various features of the surgical end effector. Furthermore, once the surgical end effector is positioned in the desired articular motion position, the articular motion system and articular motion joint must be able to hold the surgical end effector in that position during operation and the performance of surgical procedures. Such an articular motion joint configuration must also be able to withstand the external forces that the end effector experiences during use.

[0087] Various surgical instruments utilize different drive shaft configurations that transmit drive motion from a corresponding drive motion source supported by the instrument's handle or other parts of an automatic or robotic control system. These drive shaft configurations must be able to accommodate significant joint motion orientation of the end effector while effectively transmitting such drive motion across the joints of the surgical instrument. Furthermore, due to the aforementioned size limitations required by the size of the trocar into which the instrument shaft must be inserted, these drive shaft components must occupy the smallest possible space within the shaft. To meet this requirement, many drive shaft configurations include several movable elements connected in series with each other. The small size (e.g., 4 mm in diameter) and number of components result in difficult and redundant assembly procedures that increase the cost and complexity of the device.

[0088] As further described herein, an electric stapling device may include two independently rotatable drive members: a first rotary drive member configured to bring about the closure of the jaws of an end effector, and a second rotary drive member configured to bring about the firing of a staple cartridge installed within the end effector. The first and second rotary drive members are flexible and configured to extend through at least one articulated joint. In such embodiments, the first and second rotary drive members can transmit rotational operating motion through the articulated joint(s) in both non-flexible and flexible configurations. Typical rotary drive members are further described herein.

[0089] The motorized staple fastening assembly further comprises a closing drive unit having a first jaw, a second jaw, and a first rotary drive member extending through an articulated joint, and a firing drive unit having a second rotary drive member extending through an articulated joint. The second rotary drive member may be rotatable independently of the first rotary drive member. The closing drive unit may be actuated, for example, by a closing trigger, and the actuation of the closing drive unit results in the rotation of the first rotary drive member, which transmits rotational motion to a closing screw via an articulated joint. The closing drive unit further comprises a closing wedge portion screwably connected to the closing screw, the closing wedge portion engaging with the first jaw to move the first jaw from an open position to a closed position when the first rotary drive member rotates.

[0090] The firing drive unit may be actuated, for example, by a firing trigger separate from the closing trigger. The rotation of the second rotary drive member is separate from the rotation of the first rotary drive member, and the closing motion is separate from and distinct from the firing motion. The operation of the firing drive unit results in the rotation of the second rotary drive member, which transmits the rotational motion to the firing screw through an articulated joint. The firing drive unit further comprises a firing member screwably connected to the firing screw, which cam-engages with the first and second jaws and is configured to move the cutting member and / or staple firing thread when the second rotary drive member rotates.

[0091] In various cases, at least one component within a motorized stapler may be a 3D printed component. 3D printed components may be incorporated into articulated systems, closing / gripping systems, and / or firing systems, as further described herein. 3D printing technology can, in certain cases, improve the capabilities of components. For example, 3D printing may enable printed components to exhibit metamaterial properties, thereby allowing them to exhibit greater structural strength and rigidity while enabling precision in the formation of small, detailed features and optimizing other properties of the component, such as selective flexibility and / or lubricity. Typical 3D printed components for motorized staplers, further described herein, include flexible, rotatable drive members(s), e.g., serially 3D printed universal joints, firing members or I-beams, and / or staple cartridges and / or their subcomponents. In one embodiment, the staple cartridge may be a composite plastic-metal 3D printed component. 3D printing of various components and considerations therefor are further described herein.

[0092] Methods of stapling using such surgical staple assemblies can also be conceived. These methods may include obtaining a surgical staple assembly and activating a closing drive by a closing trigger, wherein the closing wedge engages with a first jaw to move the first jaw from an open position to a closed position when a first rotary drive member rotates. The method may further include activating a firing drive by a firing trigger, wherein the firing member cam-engages with the first and second jaws and advances the cutting member and staple firing thread during a firing motion when a second rotary drive member rotates. Various applications of 3D printed components in such assemblies are further described herein.

[0093] The launch element and various end-effector components are subjected to high loads during the launch stroke. The applied loads may cause deformation and / or wear of the launch element and / or end-effector components. For example, during the launch stroke, the launch element, which cam-engages with the anvil and elongated channel of the end-effector, may rest at least partially within the anvil slot within the anvil and along the bottom of the elongated channel. During launch, the anvil is in its closed position, but as the launch element moves through the end-effector, the anvil may attempt to move away from the elongated channel due to forces associated with the launch. For example, forces for forming staples, forces for cutting tissue, and reaction forces from the clamped tissue when the clamped tissue is cut and stapled. These forces are applied to the launch element during launch and may cause deformation or wear of the launch element and / or other end-effector components.

[0094] In various embodiments, end-effector components may be constructed using three-dimensional ("3D") printing to enhance component capabilities. In certain cases, 3D printing may allow components to exhibit metamaterial properties that help reduce ignition power. Metamaterials are synthetic composite materials that have structures exhibiting properties not typically found in natural materials. 3D printing is one technique used to create metamaterials for forming structures that have two or more materials. Thus, 3D printing enables the creation of complex geometric shapes and / or combinations of materials that would otherwise be too expensive and time-consuming to manufacture, or even impossible to manufacture without 3D printing technology.

[0095] In various embodiments, the launching element may be 3D printed, so that its body acts as a spring, allowing the upper cam portion and / or lower cam portion to bend and move to contact the anvil and elongated channel at an angle of reduced resistance.

[0096] Figures 24 and 25 show a launching member 41000 for use with surgical instruments, such as surgical instruments disclosed herein. The launching member 41000 is transformable from a first configuration or unloaded configuration (Figure 24) when there is no launching load to a second configuration or extended configuration (Figure 25) when there is a launching load. Additional configurations, such as an intermediate configuration between the unloaded configuration and the extended configuration, can also be conceived in response to different launching loads. The launching member 41000 comprises a proximal launching bar portion 41100 and a distal head portion 41200 extending from the launching bar portion 41100. Specifically, the launching bar portion 41100 includes a distal projection 41110 extending into a cutout portion 41250 defined at the proximal end of the distal head portion 41200. The distal projection 41110 includes an arcuate portion and a blunt distal end for driving engagement with the distal head portion 41200. This configuration allows the launch bar section 41100 to be assembled into the distal head section 41200.

[0097] The distal head portion 41200 further includes an upper portion 41210 and a lower portion 41220 that are movable relative to each other. A cutout portion 41250 is defined on both the upper portion 41210 and the lower portion 41220. Thus, the distal end of the firing bar portion 41100 engages with both the upper portion 41210 and the lower portion 41220 of the distal head portion 41200. Furthermore, the distal head portion 41200 includes a projecting nose portion 41230 that extends distally. The projecting nose portion 41230 is configured, for example, to engage and drive distally the threads of a surgical staple cartridge during the firing stroke. The projecting nose portion 41230 may be configured, for example, to disable firing lockout of a surgical instrument. Furthermore, the distal head portion 41200 includes, in certain embodiments of this disclosure, a knife portion or cutting member for cutting patient tissue during the firing stroke of the firing member 41000.

[0098] In addition to the above, the distal head portion 41200 includes a flexible portion 41240 connecting the upper portion 41210 and the lower portion 41220 of the distal head portion 41200. Specifically, the flexible portion 41240 includes an upper end 41260 defined on the upper portion 41210 and a lower end 41270 defined on the lower portion 41220. In at least one embodiment, the flexible portion 41240 is embedded within the distal head portion 41200. However, other mounting configurations for the upper portion 41220, the lower portion 41220, and the flexible portion 41240 are conceivable. For example, the entire distal head portion 41200 may be 3D printed with different materials for different parts of the distal head 41200.

[0099] In at least one embodiment, the distal head 41200 is made of a first material, and the flexible portion 41240 is made of a second material different from the first material. For example, the flexible portion 41240 may be made of aluminum, and the rest of the distal head portion 41200 may be made of stainless steel. However, other embodiments are also conceivable having different materials for the distal head portion 41200 and the flexible portion 41240, such as plastic, ABS, rubber, and / or various polymers. In the illustrated embodiment, the flexible portion 41240 is molded in the shape of an "I" with an upright portion and right-angle flanges at both ends of the upright portion, but other embodiments are also conceivable with different cross-sectional shapes of the flexible portion 41240.

[0100] In addition to the above, the distal head portion 41200 comprises an upper cam member defined on the upper portion 41210 and a lower cam member defined on the lower portion 41220. The upper and lower cam members are configured to cam-engage with the first and second jaws of the end effector of the surgical instrument in order to bring the first and second jaws closer to each other during the firing stroke. Thus, the upper portion 41210 and the lower portion 41220 may be separated to accommodate the lateral load applied to the distal head portion 41200 during the firing stroke. Specifically, as shown in Figure 25, a gap 41280 may be formed between the upper portion 41210 and the lower portion 41220 of the distal head 41200 during the firing stroke. In the illustrated embodiment, the upper portion 41210 moves away from the stationary lower portion 41240. The distal end of the launch bar 41100 includes an extension 41120, which extends beyond the height of the upper portion 41210 when the distal head portion 41200 and the flexible portion 41240 are not deformed or expanded. Furthermore, the extension 41120 of the launch bar 41100 is tall enough to accommodate the expansion of the distal head 41200. Therefore, when the distal head 41200 is expanded, the extension 41120 of the launch bar 41100 can maintain driving contact with the proximal end of the distal head 41200.

[0101] In any case, other embodiments are conceivable in which both the upper portion 41210 and the lower portion 41220 move during the firing stroke in response to the firing load. Furthermore, other embodiments are conceivable in which only the lower portion 41220 moves during the firing stroke.

[0102] In addition to the above, when the distal head 41200 extends vertically to the extended configuration, the flexible portion 41240 extends vertically while maintaining the connection between the upper portion 41210 and the lower portion 41220 of the distal head 41200. When the flexible portion 41240 is extended, the middle portion 41265 of the flexible portion 41240 may neck down or narrow to accommodate lateral loads, as depicted in Figure 25.

[0103] Figure 26 shows a surgical instrument 42000 comprising an elongated shaft 42100, an end effector 42200 extending from the elongated shaft 42100, and a launching member 42300 configured to move relative to the elongated shaft 42100 and the end effector 42200 to perform a firing stroke. The elongated shaft 42100 may be, for example, a closure tube for opening and closing a pair of jaws 42240, 42210 of the end effector 42200. The launching member 42300 comprises a proximal launching bar portion 42310 and a distal head portion 42320 extending therefrom. Specifically, the proximal launching bar portion 42310 includes a distal projection 42312 extending into a cutout portion 42336 defined at the proximal end of the distal head portion 42320. This configuration facilitates the assembly of the proximal launch bar portion 42310 onto the distal head portion 42320.

[0104] In addition to the above, the distal head portion 42320 is a two-part assembly formed from an upper portion 42330 and a lower portion 42340 that are movable relative to each other. The upper portion 42330 includes a lower foot portion 42334 projecting distally, and the lower portion 42340 includes an upper foot portion 42342 projecting proximally, which is positioned to interact with and selectively connect with the distally projecting lower foot portion 42334. The opening 42400 is defined between the distally projecting lower foot portion 42334 and the proximally projecting upper foot portion 42342 when the upper portion 42330 and the lower portion 42340 are in a collapsed configuration, as depicted in Figure 26. The opening 42400 allows the upper portion 42330 to move to some extent relative to the lower portion 42340 during the firing stroke of the distal head portion 42320, as will be discussed in more detail below.

[0105] In addition to the above, the distally projecting lower foot portion 42334 extends into a pocket or cavity 42346 within the lower portion 42340. The cavity 42346 defines a flange 42348 on the proximal end of the lower portion 42340. The flange 42348 extends toward the upper portion 42330 and prevents the distally projecting lower foot portion 42334 from detaching from the lower portion 42340. Specifically, the height of the opening 42400 is lower than the height of the flange 42348, thus preventing the upper portion 42330 and the lower portion 42340 from detaching longitudinally.

[0106] In addition to the above, the upper portion 42330 and the lower portion 42340 of the distal head portion 42320 may be connected, for example, in certain cases, via a flexible mounting member such as the flexible portion 41240 in Figure 24. Furthermore, in at least one embodiment, the upper portion 42330 and the lower portion 42340 of the distal head portion 42320 may include two completely separate components that are not mounted but are held together due to the internal geometric shapes of the elongated shaft 42100 and the end effector 42200.

[0107] In addition to the above, the upper portion 42330 includes a first cam member configured to cam-engage with a first jaw portion 42240 of the end effector 42200 during the firing stroke, and the lower portion 42340 includes a second cam member configured to cam-engage with a second jaw portion 42210 of the end effector 42200 during the firing stroke. Thus, the first and second cam members are configured to bring the first jaw portion 42240 and the second jaw portion 42210 of the end effector 42200 closer together during the firing stroke. In the illustrated embodiment, the first jaw portion 42240 includes a movable anvil, and the second jaw portion 42210 includes an elongated channel configured to receive a staple cartridge 42220. The anvil 42240 is movable relative to the elongated channel 42210 between an open position and a closed position. Furthermore, the launching member 42300 is configured to move the threads 42230 of the staple cartridge 42220 through the end effector 42200, thereby ejecting staples from the staple cartridge 42220.

[0108] During use, as the launcher 42300 advances distally from the unlaunched position depicted in Figure 26, the distal head portion 42320 advances beyond the distal end of the elongated shaft 42100, which may allow for expansion of the distal head portion 42320 under certain firing loads. The distal head portion 42320 advances into the end effector 42200 such that the upper cam member engages with the anvil 42240 and the lower cam member engages with the elongated channel 42210. Thus, the first cam member on the upper portion 42330 is cam-engaged with the movable anvil 42240 during the firing stroke, and the second cam member on the lower portion 42340 is cam-engaged with the elongated channel 42210 during the firing stroke.

[0109] The upper portion 42330 and the lower portion 42340 are capable of moving vertically to separate or move further away during the firing stroke. For example, if the anvil 42240 is in its closed position and the firing stroke is initiated, the force from staple firing, cutting, and / or patient tissue may deflect or move the anvil 42240 away from the elongated channel 42210. Expansion of the distal head portion 42320 may accommodate such movement or deflection. In particular cases, expansion of the firing member 42320 may accommodate the entry of the upper cam member on the upper portion 42330 into the anvil channel of the anvil 42200 if the anvil channel is misaligned. Furthermore, the expansion of the distal head portion 42320 is limited by the distally projecting lower foot portion 42334 and the proximal projecting upper foot portion 42342, but these feet are attracted to each other to close the space 42400 between them and eventually engage with each other to limit the degree of expansion of the distal head portion 42320.

[0110] In addition to the above, the distal head portion 42320 is advanced distally and expanded, after which the distal head portion 42320 can be retracted to return to the fixed or unfired position as illustrated in Figure 26. During retraction, the first cam surface 42338 on the upper portion 42330 engages with the second cam surface 42120 on the distal end of the elongated shaft 42100. The first cam surface 42338 and the second cam surface 42120 interact to compress the distal head 42320 to its unexpanded state (Figure 26).

[0111] In addition to the above, the lower portion 42340 of the distal head portion 42320 includes a cutout portion 42344 defined at the distal end of the lower portion 42340. The cutout portion 42344 is configured to receive the proximal nose portion 42232 of the thread 42230 inside. Thus, the distal advance of the distal head portion 42320 advances the thread 42230 through the staple cartridge 42220 and ejects the staple. Furthermore, the distal head portion 42320 includes a knife portion 42332 configured to cut the patient's tissue during the firing stroke.

[0112] Figures 27 and 28 show a staple-fastening attachment 43000 for use with surgical instruments as described herein. The staple-fastening attachment 43000 comprises an elongated shaft 43100 that can be attached to a handle and / or housing, and an end effector 43200 extending from the elongated shaft 43100. The end effector 43200 comprises a first jaw or anvil 43210 and a second jaw or elongated channel 43220. The anvil 43210 is movable between an open position and a closed position relative to the elongated channel 43220 in response to a closing movement from the closing system. The anvil 43210 has a landing portion 43212 at its proximal end. Furthermore, a medium-durometer material and / or a low-durometer material 43214 extends from the landing portion 43212. The low-durometer material 43214 may include, for example, rubber, plastic, polymer, and / or any other suitable material. Material 43214 has a lower durometer than the landing portion 43212. In one embodiment, for example, the landing portion 43212 may be metal and material 43214 may be rubber.

[0113] In addition to the above, the elongated channel 43220 is configured to receive the staple cartridge 43230 inside. The staple cartridge 43230 includes a proximal cartridge tail 43232 having substantially flat portions on both sides of the cartridge slot 43234. Typically, the cartridge tail 43232 is configured to interact with the landing portion 43212 of the anvil 43210 when the anvil 43210 is in its closed position. In the illustrated embodiment, the low-durometer material 43214 acts as a semi-compressible material between the landing portion 43212 of the anvil 43210 and the cartridge tail 43232. Thus, the anvil 43210 may float relative to the staple cartridge 43230 in response to forces applied by the closing system and / or launch system. Specifically, due to the compressible nature of the low-durometer material 43214, the anvil 43210 can bend and / or deflect relative to the staple cartridge 43230 more than would be possible without the low-durometer material 43214 present on the landing portion 43214.

[0114] Other embodiments are also conceivable in which the low-durometer material 43214 is defined as part of the anvil 43210 and is coplanar with the landing portion 43212 of the anvil 43210. In such a configuration, the low-durometer material 43214 may allow for over-closing of the anvil 43210 to the staple cartridge 43230. Specifically, the launching member engages with the anvil slot 43216 and the elongated channel 43220 to close the anvil 43200 to the staple cartridge 43230 during the initial closing operation. During the initial closing operation of the anvil 43200, the compressible low-durometer material 43214, which is coplanar with the landing portion 43212, may come into contact with the rigid cartridge tail 43232 of the staple cartridge 43230, causing interference. Because the low-durometer material 43214 is compressible, the proximal portion of the anvil 43200 can bend to overcome interference between the landing portion 43212 and the cartridge tail 43232. As the launching member advances through the stapled cartridge 43230, the low-durometer material 43214 can be further compressed against the rigid cartridge tail 43232. The two surfaces 43214, 43232 can move through the point of interference to allow the launching member to complete the firing stroke without jamming.

[0115] In addition to the above, the low-durometer material 43214 may be more compressible than the anvil 43210 and / or cartridge 43230. Furthermore, the low-durometer material 43214 may reduce the force on the launcher as it moves through the anvil 43210 and the staple cartridge slot 43234. Specifically, a launcher having an upper cam member and a lower cam member, such as those described herein, may move within the end effector 43200. For example, the upper cam of the launcher moves through the anvil slot 43216. Due to the compressibility of the low-durometer material 43214, the anvil slot 43216 may bend relative to the staple cartridge 43230. Therefore, the force applied to the upper cam member of the launcher during closure and / or firing is reduced compared to the case where the low-durometer material 43214 is not present.

[0116] In addition to the above, embodiments are also envisioned in which the low-durometer material 43214 and the extended launching members 41000 and 42320 shown in Figures 24 to 26 are incorporated into the end effector. The compressibility of the low-durometer material 43214 of the anvil, combined with, for example, the expandability of the launching members 41000 or 42320, can provide the end effector with greater variability, for example, during the firing stroke. Specifically, the low-durometer material 43214 may allow the anvil to float more relative to the cartridge, and the extended launching members 41000 and 42320 may allow for greater clearance in the alignment between the launching member flange and the anvil slot.

[0117] In various embodiments, the launching member (e.g., an I-beam or E-beam) may be constructed to have a complex 3D printed shape incorporated into the body, which may act as a spring, allowing the upper cam portion to bend and move together with the anvil shelf portion to an angle of reduced or minimal resistance. Such geometrically complex printed structures enable metamaterial behavior. For example, a metallic I-beam may have a portion that functions as a solid metal structure and an alternative portion with a geometric shape designed to allow greater bending and / or extension so that the I-beam can be deflected in position and / or direction according to the application and / or load. Representative embodiments of such I-beams are discussed in more detail below.

[0118] Figure 29 depicts a launching member 44000, comprising a main body portion 44100, a pair of upper cam members 44140 extending laterally from both sides of the main body portion 44100, and a pair of lower cam members 44150 extending laterally from both sides of the main body portion 44100. The upper cam members 44140 are configured to cam-engage with the upper jaw or anvil of an end effector during the launch stroke, and the lower cam members 44150 are configured to cam-engage with the lower jaw or elongated channel of an end effector during the launch stroke. The elongated channel is configured to receive a staple cartridge containing staples that can be ejected when the launching member 44000 advances within the staple cartridge. Typical jaws, anvils, and staple cartridges for use with the launching member 44000 are further described herein.

[0119] In addition to the above, the main body portion 44100 includes a longitudinal opening 44110 extending through the main body portion 44100 and defining a longitudinal axis LA. The main body portion 44100 further includes a distal nose portion 44130 extending distally from the main body portion 44100. The longitudinal opening 44110 is configured to receive a rotary launch driver, for example, a launch screw 261 (see, for example, Figure 16). The main body portion 44100 further includes a cutout region 44120 configured to receive a launch drive nut 44200. The launch drive nut 44200 is configured to screw into the rotary launch driver to convert the rotational motion of the rotary launch driver into translation of the launch member 44000. The launch drive nut 44200 includes a pair of lateral extending members 44210 extending from both sides of the launch drive nut 44200. A pair of laterally extending members 44210 are aligned with a pair of lower cam members 44150. Thus, the cam members 44210 and 44150 cooperate during the firing stroke to cam-engage with the lower jaw of the end effector.

[0120] In addition to the above, the launching member 44000 further comprises a flexible portion 44160 positioned between the main body portion 44100 and a pair of upper cam members 44140. In other words, the flexible portion 44160 attaches at least a portion of the upper cam members 44140 to the main body portion 44100. As seen in Figure 31, the flexible portion 44160 comprises a three-dimensional grid including an array of cavities, gaps, and / or cutouts. The array of cavities forms a plurality of arc-shaped bars 44162 arranged in an array. The flexible portion 44160 has an overall cross-sectional density that is reduced compared to the adjacent upper cam members 44140 and main body portion 44100. Therefore, the flexible portion 44160 can bend, flex, and / or deflect more than the adjacent upper cam members 44140 and main body portion 44100. As shown in Figure 31, the arched bar 44162 and the corresponding cutout region are symmetrical with respect to the main body portion 44100. However, other embodiments are conceivable in which the arched bar 44162 has various shapes and sizes on the same side and / or opposite side of the main body portion 44100. In particular cases, the array of cavities may form, for example, a linear bar. In at least one embodiment, the flexible portion 44160 comprises, for example, a three-dimensional honeycomb grid. The three-dimensional grid of the flexible portion 44160 may have a reduced density compared to the adjacent portion. Furthermore, the flexible portion 44160 may have a significantly reduced filling rate compared to the adjacent portion.

[0121] In addition to the above, as shown in Figure 31, the flexible portion 44160 extends longitudinally from the distal end of the upper cam member 44140 along only a portion of the upper cam member 44140 and terminates in the middle portion of the upper cam member 44140. Therefore, the distal end of the upper cam member 44140 is more flexible than the proximal end of the upper cam member 44140. Other embodiments are also conceivable in which the flexible portion 44160 extends along the entire length of the upper cam member 44140 and / or only to the proximal end of the upper cam member 44140. Furthermore, other embodiments are still conceivable in which the flexible portion 44160 is located in the center of the upper cam member 44140, with more rigid portions at the proximal and distal ends.

[0122] In addition to the above, in at least one embodiment, the launching member 44000 may be constructed using a 3D printing process. Conventionally, filled-wall and solid-wall parts have been used to manufacture lightweight and strong objects. 3D printed parts are manufactured with a specific filling density. The printing process uses cross-hatching or other patterns on the inner surface to form compartments within the filled portion of the 3D printed part. The density of this pattern is referred to as the filling density. For example, it is common to have walls 1-2 mm thick with 25-35% of the part solid inside the walls. When constructing parts using powder-based processes such as 3D printing, it is important to note that the powder must have escape holes to ensure powder reuse after the part is manufactured. The filling of the part can be 2D, such as honeycomb, or 3D, such as gyrod. Different patterns have different strength profiles. For example, a pattern with larger compartments may be more flexible than a pattern with smaller compartments. Due to the degrees of freedom of the geometric shape, the geometric shape can be made variablely thicker and thinner to ensure that bending can occur at desired locations and by desired amounts.

[0123] By using different geometric shapes and filling densities at different locations on the launch member 44000, different degrees of deformation and / or deformation in different directions can be achieved. In certain cases, the leading edge of the upper cam portion 44140 may have a different filling density or filling matrix / filling shape than the adjacent portion of the launch member 44000 in order to maintain the rigidity of the proximal end of the upper cam portion 44140, as shown in Figure 31. Increasing the deflection of the leading edge of the upper cam portion 44140 may facilitate alignment of the upper cam portion 44140 with the anvil shelf portion at the start of the launch motion, which may avoid jamming or sticking of the launch member in certain cases, such as when thick and / or tough tissue is clamped between the jaws. Other embodiments are also conceivable in which the center of the upper cam portion 44140 is flexible and both ends are more rigid. Thus, by changing the geometric shape of the launch member using 3D printing, the position and amount of bending can be controlled based on the amount of expected force.

[0124] Figures 32 and 33 depict a launching member 45000, comprising a main body portion 45100, a pair of upper cam members 45140 extending laterally from both sides of the main body portion 45100, and a pair of lower cam members 45150 extending laterally from both sides of the main body portion 45100. The upper cam members 45140 are configured to cam-engage with the upper jaw or anvil of an end effector during the launch stroke, and the lower cam members 45150 are configured to cam-engage with the lower jaw or elongated channel of an end effector during the launch stroke. The elongated channel is configured to receive a staple cartridge containing staples that can be ejected when the launching member 44000 advances within the staple cartridge. Typical jaws, anvils, and staple cartridges for use with the launching member 45000 are further described herein.

[0125] In addition to the above, the main body portion 45100 includes a longitudinal opening 45110 extending through the main body portion 45100, similar to the longitudinal opening 44110 (see Figure 29). The longitudinal opening 45110 is configured to receive a rotary launch driver, for example, a launch screw 261 (see, for example, Figure 16), as described above. The main body portion 45100 further includes a distal nose portion 45130 extending distally from the main body portion 45100. The main body portion 45100 further includes a cutout region 45120 configured to receive a launch drive nut 45200. The launch drive nut 45200 is configured to screw into the rotary launch driver to convert the rotational motion of the rotary launch driver into translation of the launch member 45000. The launch drive nut 45200 includes a pair of laterally extending cam members 45210 extending from both sides of the launch drive nut 45200. A pair of laterally extending cam members 45210 are aligned with a pair of lower cam members 45150. Thus, the cam members 45210 and 45150 cooperate during the firing stroke to cam-engage with the lower jaw of the end effector.

[0126] In addition to the above, the launching member 45000 further comprises a flexible portion 45160 positioned between the upper cam member 45140 and the lower cam members 45150 and 45210. The flexible portion 45160 comprises a first plurality of arc-shaped slots 45170 extending laterally through the main body portion 45100, and a second plurality of arc-shaped slots 45180 extending laterally through the main body portion 45100. In the illustrated embodiment, the first plurality of arc-shaped slots 45170 are curved in a direction similar to a rear C shape, and the second plurality of arc-shaped slots are curved in the opposite direction similar to a front C shape. However, other embodiments having different curvatures or combinations of curvatures for the arc-shaped slots 45170 are also conceivable. Furthermore, although the illustrated embodiment depicts five first arc-shaped slots 45170 and five second arc-shaped slots 45180, other embodiments are also conceivable in which there are more or fewer than five arc-shaped slots with respect to each of the first multiple arc-shaped slots 45170 and each of the second multiple arc-shaped slots 45180.

[0127] In any case, the main body portion 45100 further comprises a first cutout region 45175 on its distal end defined by a first plurality of arc-shaped slots 45170, and a second cutout region 45185 on its proximal end defined by a second plurality of arc-shaped slots 45180. The arc-shaped slots 45170, 45180 and the cutout regions 45175, 45185 allow the launching member 45000 to bend and / or deflect when a load is applied to it, as will be discussed in more detail below.

[0128] Referring primarily to Figure 33, the anvil channel or anvil shelf 45300 and the elongated channel 45400 for receiving the staple cartridge are depicted with dashed lines for simplification. When the firing member 45000 is driven within the end effector during use, the upper cam member 45140 is configured to cam-engage with the anvil (i.e., move along the anvil shelf 45300) during the firing stroke. Furthermore, the lower cam members 45150 and 45210 are configured to cam-engage with the bottom of the elongated channel 45400 during the firing stroke. During the firing stroke of the firing member 45000, the upper cam member 45140 may be subjected to a lateral force F applied by the anvil shelf 45300 as the anvil shelf 45300 moves away from the elongated channel 45400. For example, the lateral force F may result from clamping of patient tissue, firing of staples, or cutting of patient tissue. In at least one embodiment, a lateral force F may be applied to the upper cam member 45150, for example, when entering the anvil channel. In any case, the launch member 45000 is configured to bend and / or deflect by the flexible portion 45160 during the launch stroke. Specifically, in Figure 32, the launch member 45000 is in a relaxed state corresponding to the unloaded configuration, and in Figure 33, the launch member 45000 is in an unrelaxed or deflected state corresponding to the loaded configuration.

[0129] In addition to the above, due to the lateral force F applied to the upper cam member 45140, the upper cam member 45140 rotates clockwise, causing the flexible portion 45160 and the main body portion 45100 to bend and / or deflect, allowing the launch member 45000 to change shape based on the applied load. Specifically, when a lateral force F is applied, the first plurality of arc-shaped slots 45170 are configured to expand, and the second plurality of arc-shaped slots 45180 are configured to compress. Furthermore, when a lateral force F is applied, the first cutout region 45175 expands and the second cutout region 45185 compresses. Therefore, the launch member body 45100 can bend and / or deflect to respond to the lateral force F.

[0130] In addition to the above, during use, the upper cam member 45140 is configured to move along the anvil shelf portion 45300 within the longitudinal anvil slot. When the upper cam member 45140 first enters the anvil slot, it may become misaligned due to changes in the amount of tissue (i.e., thick and thin tissue) gripped between the jaws. Therefore, the flexible portion 45160 allows the upper cam member 45140 to bend and / or deflect, for example, to properly align the upper cam member 45140 with the anvil slot. Furthermore, changes in the amount of tissue gripped between the jaws may cause the anvil shelf portion 45300 to move away from the elongated channel 45400 during the firing stroke of the firing member 45000. Therefore, the upper cam member 45140 may become misaligned with the anvil slot during firing. However, the flexible portion 45160 allows the upper cam member 45140 to bend and / or deflect to compensate for changes in tissue volume, in order to prevent the upper cam member 45140 from jamming in the anvil slot if the upper cam member 45140 is not properly aligned in the anvil slot.

[0131] In addition to the above, in at least one embodiment, the launch member 45000 may have a longitudinal slot extending through the flexible portion 45160, allowing one side of the launch member 45000 to bend at least partially independently of another side of the launch member 45000. The longitudinal slot may be similar to, for example, the longitudinal slot 46170 (see Figure 34), which will be discussed in more detail below.

[0132] Figures 34 to 36 depict a launching member 46000, comprising a main body portion 46100, a pair of upper cam members 46140 extending laterally from both sides of the main body portion 46100, and a pair of lower cam members 46150 extending laterally from both sides of the main body portion 46100. The upper cam members 46140 are configured to cam-engage with the upper jaw or anvil of an end effector during the launching stroke, and the lower cam members 46150 are configured to cam-engage with the lower jaw or elongated channel of an end effector during the launching stroke. The elongated channel is configured to receive a staple cartridge containing staples that can be ejected when the launching member 46000 advances within the staple cartridge. Typical jaws, anvils, and staple cartridges for use with the launching member 46000 are further described herein.

[0133] In addition to the above, the main body portion 46100 includes a longitudinal opening 46110 extending through the main body portion 46100 and defining a longitudinal axis LA. The longitudinal opening 46110 is configured to receive a rotary launch driver, for example, a launch screw 261, as described above (see, for example, Figure 40). The main body portion 46100 further includes a distal nose portion 46130 extending distally from the main body portion 46100. The main body portion 46100 further includes a cutout region 46120 configured to receive a launch drive nut 46200. The launch drive nut 46200 is configured to screw into the rotary launch driver to convert the rotational motion of the rotary launch driver into translation of the launch member 46000. The launch drive nut 46200 includes a pair of laterally extending cam members 46210 extending from both sides of the launch drive nut 46200. A pair of laterally extending cam members 46210 are aligned with a pair of lower cam members 46150. Thus, the cam members 46210 and 46150 cooperate during the firing stroke to cam-engage with the lower jaw of the end effector.

[0134] In addition to the above, the launch member 46000 further comprises a flexible portion or grid portion 46160 positioned between the upper cam member 46150 and the lower cam member 46150. In the illustrated embodiment, the grid portion 46160 is branched by longitudinal slots 46170 extending parallel to the longitudinal axis LA. The longitudinal slots 46170 extend through the main body portion 46100 from the proximal end to the distal end. Thus, the grid portion 46160 is divided into a first side 46180 and a second side 46190. The first side 46180 of the grid portion 46160 comprises a plurality of slots 46182 oriented to traverse the longitudinal axis LA in a first direction. The second side 46190 of the grid portion 46160 comprises a plurality of slots 46192 oriented to traverse the longitudinal axis LA in a second direction opposite to the first direction. The plurality of slots 46182, 46192 reduce the overall cross-sectional density of the launch member 46000 within the grid portion 46160. In other words, the grid portion 46160 has a lower density (e.g., lower filling rate) than adjacent portions of the main body portion 46100 of the launch member 46000. Furthermore, longitudinal slots 46170 branching the grid portion 46160 allow the first side 46180 of the grid 46160 to slide past the second side 46190 of the grid 46160, and vice versa, and / or allow the first side 46180 of the grid 46160 to extend vertically while the second side 46190 is compressed vertically, and vice versa. Without the longitudinal slot 46170, the sliding and deflection of the first side 46180 and the second side 46190 relative to each other would be restricted.

[0135] In addition to the above, the first side 46180 is provided with a notch 46185 at the proximal end of the main body portion 46100, and the second side 46190 is provided with a notch 46195 at the proximal end of the main body portion 46100. The notches 46185 and 46195 provide greater bending and / or deflection of the proximal end of the main body portion 46100 compared to the distal end of the main body portion 46100. Furthermore, in the illustrated embodiment, the notches 46185 and 46195 are located on the proximal end of the main body portion 46100. However, other embodiments are conceivable in which the notches 46185 and 46195 are located on the distal end of the main body portion 46100 for the opposite effect. Furthermore, other embodiments are conceivable in which the notches have notches on both the proximal and distal ends of the main body portion 46100 (see Figure 38 and the accompanying description below).

[0136] During use, as the launching member 46000 is advanced into the end effector, the upper cam member 46140 engages with the upper jaw or anvil of the end effector, and the lower cam members 46150 and 46210 engage with the lower jaw hand or elongated channel of the end effector. Thus, the grid portion 46160 is configured such that the upper cam member 46140 and the lower cam members 46150 and 46210 bend and / or deflect relative to the main body portion 46100 to accommodate lateral forces during the firing stroke.

[0137] The main body portion 46100 and the grid portion 46160 can be constructed from various geometric shapes and materials to accommodate a desired stress profile within the launch member 46000 during the firing stroke. For example, the launch member 46000 can be constructed using 3D printing or an equivalent process. In at least one embodiment, the main body portion 46100 is 3D printed as a single unit having a main body portion containing a first material and a grid portion 46160 containing a second material different from the first material. Furthermore, the first material may have a first density, and the second material may have a second density different from the first density.

[0138] In addition to the above, 3D printing generally produces structures that have some degree of space (i.e., are not completely solid at the micro level). As mentioned above, the 3D printing process uses cross-hatching or other patterns on the inner surface housed within a more rigid solid wall structure. The density of this pattern within the solid wall is called the infill density. The infill density can be varied throughout the 3D printing process to produce components with different infill densities in different parts of the component. When different infill parts contain different infill densities, they essentially contain different densities at the micro level. In other words, by varying the different infill parts, it is possible to create different microdensities within a component.

[0139] In addition to the above, other embodiments are conceivable in which the filling density is uniform throughout the entire part. In such cases, flexibility can be built into the part from macrogeometric shapes such as slots, cutouts, and holes as the 3D structure is constructed around it. For example, the launch member 46000 may have a perfectly uniform filling density. In such a case, slots 46182 and 46192 define a bar structure between the slots 46182 and 46192, and the bar structure has, for example, the same filling density as the rest of the launch member 46000.

[0140] Figure 37 depicts a graphical representation of the forces applied to the launch member 46000 during the launch stroke. In the illustrated embodiment, the greater the force applied to the launch member 46000, the darker the shading. The forces are shown in the legend of Figure 37 as pounds per square inch (PSI). In the illustrated embodiment, a load of 150 pounds on the distal end of the launch member 46000 resulted in a 1-degree bend during the finite element analysis simulation.

[0141] Figures 38 and 39 show a launch member 48000 that is similar to the launch member 46000 in many embodiments and has the differences discussed herein. The launch member 48000 comprises a flexible portion or grid portion 48160. The grid portion 48160 is branched by longitudinal slots that divide the grid portion 48160 into a first side 48180 and a second side 48190. The first side 48180 comprises a proximal notch 48182 defined at the proximal end of the launch member 48000 and a distal notch 48184 defined at the distal end of the launch member 48000. The notches 48182 and 48184 are V-shaped or triangular cutouts. The proximal notch 48182 is larger along its upper edge, while the distal notch 48184 is larger along its lower edge. The second side 48190 includes a proximal notch and a distal notch opposite to the proximal notch 48182 and distal notch 48184. Thus, the first side 48180 of the grid portion 48160 is an inverted mirror image of the second side 48190 of the grid portion 48160. Similar to the launch member 46000, the launch member 48000 includes a plurality of slots oriented within the grid portion 48160. Specifically, the first side 48180 includes a plurality of slots 48186 oriented in a first direction traversing the longitudinal axis LA of the launch member 48000. Furthermore, the second side 48190 includes a plurality of slots 48196 oriented across the longitudinal axis LA in a second direction opposite to the first direction.

[0142] Figure 40 depicts a model of a flexible portion 49000 configured for use with a launching member of a surgical instrument, such as a launching member described herein. The flexible portion 49000 is configured to bend forward, backward, and sideways to accommodate the load on the launching member during the launch stroke. The flexible portions 44160, 45160, 46160, and 48160 described herein may be configured to bend as shown in Figure 40, similarly resulting in front-to-back and side-to-side bending of the I-beam. Embodiments in which the flexible portion 49000 is part of or substitutes for the flexible portions 44160, 45160, 46160, and 48160 within a launching member described herein are also conceivable. The flexible portion 49000 is configured to transition from a relaxed state 49100 (shown by dashed lines) to a bent state or a deflected state 49100' (shown by solid lines) when a force is applied to the flexible portion 49000.

[0143] In the illustrated embodiment, the applied force is applied to the upper member 49100 of the flexible member 49000, while the base 49120 of the flexible member 49000 is held stationary. The upper member 49100 and the base 49120 are connected by a first vertical member 49130 and a second vertical member 49140 that intersect to form an X-configuration. When a force is applied to the upper member 49100 during use, the upper member 49100 transitions to a deflected state 49110', the first vertical member 49130 transitions to a deflected state 49130', and the second vertical member 49140 transitions to a deflected state 49140'. The first vertical member 49130 and the second vertical member 49140 can be deflected to accommodate various loads applied to the upper member 49100.

[0144] It should be understood that any of the individual features of the flexible portions 44160, 45160, 46160, 48160, and 49000 can be used in combination with each other. For example, a flexible portion 44160 positioned between the upper cam member 44140 and the main body portion 44100 may be incorporated into the launch members 45000, 46000, and / or 48000. Furthermore, a flexible portion 44160 may be incorporated into any of the lower cam members of the launch members 44000, 45000, 46000, 48000, and 49000 to provide greater flex in the lower cam member in certain cases.

[0145] 3D printing may be utilized, in particular, in similar approaches for various instrument components described herein. For example, to house a rotary drive screw within an elongated channel of a surgical instrument, the elongated channel may include a distal support bearing or support washer for supporting the distal end of the rotary drive screw. In at least one embodiment, the distal support bearing may be 3D printed to include a compressible portion that, when compressed in a first direction, expands in a second direction across the first direction to increase the bearing surface area between the distal support bearing and the rotary drive screw. As a result, the connection between the rotary drive screw and the distal support bearing is improved in certain cases due to a reduction in bearing load achieved by increasing the bearing surface area.

[0146] Channel retainers and various end-effector components are subjected to significant deflection and longitudinal loads during the operation of surgical instruments. Standard materials for these components consist of aluminum and stainless steel, but their tensile and deflection capabilities are limited. For example, while forces of 250–300 pounds may be applied longitudinally to a channel retainer during surgical operation, the acceptable longitudinal bending may be less than 0.08 inches.

[0147] A composite component may include different materials for different parts to obtain complex part geometric shapes, such as coupling mechanisms, alignment keyways, or open sliding passages, using a first material (e.g., plastic), while also supporting longitudinal stress and strain loads during surgical operation by maintaining appropriate strength, stiffness, and / or rigidity using a second material (e.g., metal). Metal parts within a composite component may be flexible in one plane but rigid or inflexible in another. For example, a metal part may allow lateral bending but restrict longitudinal elongation. Furthermore, plastic materials can act as gap fillers and connective materials between metal substrates, while also enabling rich and complex geometric shapes for feature parts. For example, a flexible material such as low-durometer plastic may be used as the body portion for an end-effector component. The plastic body portion may include a metal substrate portion defined within it to withstand load forces during operation while the plastic body provides the keying and alignment mechanism. Such laminated components can be constructed using 3D-printed plastic and metal substrate inserts.

[0148] For example, a channel holder for use with a surgical instrument may comprise a first metal substrate, a second metal substrate connected to the first metal substrate, and a plastic portion constructed around the first and second metal substrates. The channel holder is positioned between the handle and the end effector of the surgical instrument. Furthermore, the channel holder may include alignment and connection features incorporated into the plastic body to facilitate attachment to the surgical instrument.

[0149] Figures 41–43 illustrate a channel holder 50000 for use with surgical instruments as described herein. In various embodiments, the proximal end of the channel holder 50000 may be connected to the handle and / or housing of the surgical instrument, and the distal end of the channel holder 50000 may be connected to the articular joint and / or end effector of the surgical instrument. In such cases, the channel holder 50000 acts as the longitudinal spine portion of the surgical instrument. Furthermore, the channel holder 50000 may support the articular actuator, firing actuator, and / or closing actuator of the surgical instrument. In at least one embodiment, the channel holder 50000 withstands the load of the closing tube surrounding the channel holder 50000. A force is applied to the channel holder 50000 as the closing tube advances and acts on the end effector. Therefore, the channel holder 50000 may stretch and deflect due to the load force exerted by the closing tube.

[0150] In addition to the above, the proximal end of the channel retainer 50000 is provided with a notch 50130 to facilitate attachment of the channel retainer 50000 to the handle and / or housing of a surgical instrument. The distal end of the channel retainer 50000 is provided with a notch 50120 to facilitate attachment of the channel retainer to the articular joint and / or end effector of the surgical instrument. However, other embodiments having different mounting features for connecting the channel retainer 50000 to a surgical instrument are also conceivable.

[0151] In addition to the above, the channel holder 50000 comprises a main body portion 50100, a first base material portion 50300, and a second base material portion 50400. The channel holder 50000 further comprises a longitudinal slot 50110 defined inside it for receiving various actuators of a surgical instrument. For example, a launching member extending from the handle or housing of a surgical instrument may extend into the longitudinal slot 50110. In any case, the longitudinal slot 50110 divides the channel holder 50000 in half, with the first base material portion 50300 and the second base material portion 50400 positioned on opposite sides of the slot 50110 (i.e., the channel holder 50000 is symmetrical). In at least one embodiment, the main body portion 50100 is 3D printed together with the first base material portion 50300 and the second base material portion 50400 defined inside it. In other words, the main body portion 50100 is constructed around the first base material portion 50300 and the second base material portion 50400. In at least one embodiment, the main body portion 50100 is made of plastic, and the base material portions 50300 and 50400 are made of metal. The base material portions 50300 and 50400 may be made of, for example, stamped metal sheets. Other embodiments are also conceivable in which the base material portions 50300 and 50400 include a material that is, for example, more rigid and / or denser than the main body portion 50100.

[0152] As shown in Figure 43, the first base material portion 50300 is positioned within the main body portion 50110 at its proximal end. Each first base material portion 50300 has a first lateral flange 50310 at its distal end. The first lateral flange 50310 extends toward the longitudinal slot 50110. The second base material portions 50400 are positioned within the main body portion 50100 and each has a first opening 50410 at its proximal end and a second opening 50420 at its distal end. The first base material 50300 and the second base material 50400 are positioned so that the first opening 50410 receives the first lateral flange 50310, thereby operably connecting the first base material portion 50200 and the second base material portion 50400 within the main body portion 50100. In other words, the first base material portion 50300 and the second base material portion 50400 are at least partially embedded and / or enclosed within the main body portion 50100.

[0153] These substrates can form multi-interlocking load-sharing assemblies consisting of molded components within a 3D-printed assembly. In certain cases, the interlocking of molded components within a 3D-printed assembly can be used to combine components that are not viable alternatives for injection molding due to the shrinkage of composite materials on elongated metal components during the molding process, thereby potentially accumulating internal stresses and shear properties within the assembly. For example, elongated assemblies such as channel retainers may be better suited to 3D printing around the metal components being interlocked.

[0154] In addition to the above, each of the first base material portions 50300 is provided with a second lateral flange 50320 located at its proximal end and extending away from the longitudinal slot 50110. The second lateral flange 50320 is constructed and / or embedded within the body portion 50100 so as to extend behind the proximal notch 50310 defined within the body portion 50100. Thus, the first base material portions 50300 are at least partially restricted from moving longitudinally within the body portion 50100 due to their engagement with the proximal notch 50310. Furthermore, the alignment notch 50310 may be used to mount and align the channel holder 50000 within the handle or housing of a surgical instrument. Thus, the first base material portions 50300 within the proximal end provide additional support to the channel holder 50000 to facilitate mounting to a surgical instrument. Other embodiments are also conceivable in which the first base material portion 50300 is located at both the proximal and distal ends to facilitate attachment to surgical devices. In at least one embodiment, the main body portion 50100 includes keying features, alignment features, and / or linking features for use with surgical instruments.

[0155] The first base material portion 50300 and the second base material portion 50400 may include a metal material with higher rigidity to withstand the loads and tensile forces that the channel holder 50000 experiences during the operation of the surgical instrument.

[0156] In addition to the above, the first substrate portion 50300 and / or the second substrate portion 50400 include a flexible circuit board and / or other integrated electronic equipment supported or fixed thereto. During manufacturing, the 3D printing material for the main body portion 50100 can be overprinted around the substrate portions 50300 and 50400 without directly adhering the construction material to the electronic equipment of the substrate portions 50300 and 50400. By preventing direct application of the 3D construction material onto the substrate portions 50300 and 50400, the risk of damage to the substrate portions 50300 and 50400 and their electronic components is reduced. For example, referring mainly to Figure 43, there are various gaps 50500 between the substrate portions 50300 and 50400 and the main body portion 50100. Therefore, the channel holder 50000 is configured so that at least a portion of the substrate portions 50300 and 50400 is not directly 3D printed on it. Electronic components may be positioned in locations not directly 3D printed, thereby suppressing heat transfer to the electronic components due to localized heat and / or accidental damage. However, other embodiments are also conceivable in which the substrate portions 50300, 50400 are completely enclosed and surrounded by the 3D construction material of the main body portion 50100.

[0157] As described above, the channel holder 50000 may be constructed by 3D printing. For example, a metal substrate such as a base portion 50300 is introduced before the 3D construction begins, and the 3D plastic structure is mounted thereon. Partially through the 3D construction, the construction may be stopped by an upright alignment feature to allow the creation of a perimeter construction flange. The perimeter construction flange allows the introduction of, for example, another intermediate metal support plate or base portion 50400. In at least one embodiment, the base portions 50300, 50400 may be aligned to have a connecting plastic feature (e.g., a notch 50130) that prevents movement of the base portions 50300, 50400 within the body portion 50100, while also preventing shearing of the body portion 50100. In at least one embodiment, the channel holder 50000 is a sandwiched laminate composed of a metal plate having 3D plastic printed connecting and assembly features. The metal plate can withstand load and tensile characteristics, and the 3D printed element is configured to provide all keying, alignment, lateral support, and connecting features with adjacent systems. By 3D printing channel holders in this manner, complex plastic interface features can be attached to load-bearing metal subframes within and around 3D constructs.

[0158] In addition to the above, the stamped stainless steel parts may have lateral flange bends at both ends for attachment to the elongated shafts and / or articular joints of surgical instruments. The flanges may be positioned within the 3D printer with the flanges away from the print head path. The 3D construction is then continued to form the remainder of the channel retainer. Thus, the lateral flange bends extend from the 3D printed channel retainer for attachment to the surgical instrument. In other words, the lateral flange bends are not overprinted in the 3D printed material, extend from the 3D printed material, and are attachable to the surgical instrument.

[0159] In addition to the above, other embodiments are conceivable that have 3D printed laminated structures comprising a plastic body and a metal substrate for various end-effector components. For example, a staple cartridge, an elongated channel configured to receive a staple cartridge, and / or anvil may be constructed as a 3D printed laminate having plastic and metal materials. Thus, embodiments are also conceivable in which other end-effector components utilize a plastic body for all keying and alignment features, while the metal substrate withstands stretching and deflection loads during operation.

[0160] In addition to the above, in conventional insert molded parts, creating features such as undercuts, internal voids, internal spaces, and / or features that traverse the mold's parting line (i.e., more than 3 degrees from the mold's parting axis) can be difficult and costly to manufacture in certain cases. The 3D printed plastic body described above may, for example, have undercuts, internal voids, and / or laterally aligned features for connecting components.

[0161] Figures 44 and 45 depict a surgical instrument 51000 comprising a launch bar support 51020, a launch bar 51010, and an overmolded sleeve 51030. The launch bar support 51020 comprises two lateral plates 51022 and 51024 positioned on both sides of the launch bar 51010. In the illustrated embodiment, the launch bar 51010 comprises a laminated launch bar constructed from several layers. Other embodiments in which the launch bar is a single, integrated structure are also conceivable. In any case, the launch bar support 51020 prevents buckling of the launch bar 51010 during launch and / or articulation of the end effector 51000. In certain cases, the launch bar support 51020 may be identical to the launch bar support disclosed in U.S. Patent Application No. 15 / 635,808, filed June 28, 2017, which are incorporated herein by reference in their entirety. Furthermore, the launch bar support 51020 comprises a flexible portion 51040 positioned within the articulated joint of the surgical instrument 51000. Specifically, Figure 44 shows the surgical instrument 51000 in a non-articulated orientation, and Figure 45 shows the surgical instrument 51000 in an articulated configuration.

[0162] The launch bar support 51020 is defined within an overmolded sleeve 51030 that extends along the articular joint of the surgical instrument 51000. In other words, the overmolded sleeve 51030 contains and / or encapsulates the launch bar support 51020 within itself. In at least one embodiment, the overmolded sleeve 51030 may be a plastic 3D printed material constructed around the launch bar support 51020 to embed and / or encapsulate the launch bar support 51020 within itself. Thus, the overmolded sleeve 51030 and the launch bar support 51020 constitute a substantially integrated part. Furthermore, the integrated part formed from the overmolded sleeve 51030 and the launch bar support 51030 comprises a longitudinal slot 51032 defined within it. The longitudinal slot 51032 is configured to receive the launch bar 51010 and to allow the launch member 51010 to translate within it.

[0163] Figure 46 depicts an anvil 52000 for use with surgical instruments such as those described herein. The anvil 52000 comprises a tissue contact surface 52020 and a longitudinal slot 52030 for receiving a portion of a projectile. The anvil 52000 further comprises an anvil slot 52040 extending longitudinally along at least a portion of the anvil 52000. In the illustrated embodiment, the anvil slot 52040 is plus-shaped, but other embodiments are conceivable in which the anvil slot 52040 is T-shaped with a flat top. The reader will understand that alternative geometric shapes and forms of the anvil slot 52040 can be conceived. In any case, the anvil 52000 comprises a compliant portion 52050 extending longitudinally along at least a portion of the anvil slot 52040. In the illustrated embodiment, the compliant portion 52050 is positioned around the anvil slots 52040 on all sides. However, other embodiments are also conceivable in which the compliant portion 52050 is located only on the pair of anvil slot shelf portions 52060 of the anvil 52000.

[0164] In at least one embodiment, the compliant portion 52050 comprises a material that is more compressible than the rest of the anvil 52000. For example, the compliant portion 52050 may comprise a material that is less dense or softer (i.e., has a lower number on the Mohs hardness scale) than the rest of the anvil 52000 material. In at least one embodiment, the compliant portion 52050 may be made of brass or bronze, and the rest of the anvil 52000 may be made of stainless steel. In any case, the upper pin or upper cam member of the launching member (i.e., I-beam or E-beam) may move along the compliant portion 52050 during firing. Thus, the body of the anvil 52000 is more rigid, the anvil slot 52040 is more flexible and / or more accommodating, facilitating greater flexibility of the launching member during firing. Furthermore, the compliant portion 52050 may be smoother than the rest of the anvil 52000 to further facilitate the sliding of the upper pin of the launching member within the anvil slot 52040.

[0165] In addition to the above, the anvil 52000 may be constructed using 3D printing to position the compliant portion 52050 within the body of the anvil 52000. For example, the 3D printer may begin by constructing stainless steel upward from the tissue contact surface 52020. The 3D construction may be stopped to insert the compliant member 52050, and then construction may continue to encapsulate the compliant member 52050 within the stainless steel 3D printed material of the anvil 52000. Thus, the compliant member 52050 and the anvil 52000 may be 3D printed to produce a substantially integrated part having two different materials. Other embodiments having three or more materials 3D printed in the anvil 52000 are also conceivable.

[0166] Various aspects of the subject matter described herein will be illustrated in the following examples.

[0167] Example 1 - A launching member for use with a surgical instrument comprising an anvil and an elongated channel configured to receive a staple cartridge. The launching member comprises a body portion configured to be driven through a launching stroke; a first cam member extending laterally from the body portion and configured to cam-engage with the anvil during the launching stroke; a second cam member extending laterally from the body portion and configured to cam-engage with the elongated channel during the launching stroke; and a grid portion including a pattern of spaces formed within the launching member. The grid portion is configured to bend more easily than adjacent portions of the launching member due to the load during the launching stroke.

[0168] Example 2 - The launching member according to Example 1, wherein the grid portion is positioned midway between the first cam member and the second cam member.

[0169] Example 3 - The launching member according to Example 1 or 2, further comprising a longitudinal slot extending longitudinally through the launching member, wherein the longitudinal slot is configured to branch the grid portion into a first portion on the first side of the longitudinal slot and a second portion on the second side of the longitudinal slot, and the grid portion is deflected in opposite directions on both sides of the longitudinal slot.

[0170] Example 4 - The launching member according to Example 3, wherein the spatial pattern comprises a first plurality of slots in a first portion and a second plurality of slots in a second portion.

[0171] Example 5 - The launching member according to Example 4, wherein the first plurality of slots are oriented in a first direction, and the second plurality of slots are oriented in a second direction opposite to the first direction.

[0172] Example 6 - The launching member according to Example 4 or 5, wherein the first plurality of slots are parallel to each other and the second plurality of slots are parallel to each other.

[0173] Example 7 - The launching member according to Example 1, 2, 3, 4, 5, or 6, wherein the grid portion connects at least a portion of the first cam member to the main body portion.

[0174] Example 8 - A launching member according to Example 1, 2, 3, 4, 5, 6, or 7, wherein the spatial pattern defines a plurality of arc-shaped bars connecting the first cam member and the main body portion.

[0175] Example 9 - The launching member according to Example 8, wherein multiple arc-shaped bars are arranged in an array.

[0176] Example 10 - A launching member according to Example 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein the spatial pattern includes an array of intersecting diagonal slots.

[0177] Example 11 - A launching member according to Example 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the grid portion has lower rigidity than the first cam member and the main body portion.

[0178] Example 12 - An end effector comprising an anvil, an elongated channel configured to receive a staple cartridge, and a firing member. The firing member comprises a body portion, a first cam member extending laterally from the body portion and configured to cam-engage with the anvil during the firing stroke of the firing member, a second cam member extending laterally from the body portion and configured to cam-engage with the elongated channel during the firing stroke, and a flexible portion positioned between the first cam member and the body portion. The flexible portion comprises a three-dimensional grid comprising an array of cavities.

[0179] Example 13 - The end effector according to Example 12, wherein a hollow array defines multiple arc-shaped bars.

[0180] Example 14 - The end effector according to Example 12 or 13, wherein the flexible portion has a first rigidity, the main body portion and the first cam member have a second rigidity, and the first rigidity and the second rigidity are different.

[0181] Example 15 - A launching member for use with a surgical instrument having a first jaw and a second jaw. The launching member comprises a main body portion configured to move longitudinally through a launching stroke; a first cam member extending laterally from the main body portion and configured to cam-engage with the first jaw during the launching stroke; a second cam member extending laterally from the main body portion and configured to cam-engage with the second jaw during the launching stroke; and a low-density portion including a flexible grid configured to bend more easily than adjacent portions of the launching member due to the load during the launching stroke.

[0182] Example 16 - The launching member according to Example 15, wherein the flexible grid is deflected by a first amount when the first cam member is under load, and the main body portion adjacent to the flexible grid is deflected by a second amount when the first cam member is under load, with the first amount being greater than the second amount.

[0183] Example 17 - The launching member according to Example 15 or 16, wherein the main body portion has a first rigidity, the flexible grid has a second rigidity, and the first and second rigidities are different.

[0184] Example 18 - A launching member according to Example 15, 16, or 17, wherein the flexible grid is arranged in a pattern and comprises a plurality of slots defined within the main body portion.

[0185] Example 19 - A launching member according to Example 15, 16, 17, or 18, wherein the main body portion includes a first filling density and the low-density portion includes a second filling density, and the first and second filling densities are different.

[0186] Example 20 - The launch member according to Example 15, 16, 17, 18, or 19, further comprising a longitudinal slot extending longitudinally through the launch member, wherein the longitudinal slot branches the flexible grid into a first portion on the first side of the longitudinal slot and a second portion on the second side of the longitudinal slot.

[0187] Example 21 - The launching member according to Example 20, wherein the first portion comprises a plurality of slots oriented in a first direction, and the second portion comprises a plurality of slots oriented in a second direction opposite to the first direction.

[0188] Example 22 - A launching member for use with a surgical instrument comprising an anvil and an elongated channel configured to receive a staple cartridge, the launching member comprising: a body portion configured to be driven through a firing stroke; a first cam member extending laterally from the body portion and configured to cam-engage with the anvil during the firing stroke; a second cam member extending laterally from the body portion and configured to cam-engage with the elongated channel during the firing stroke; and a flexible portion. The flexible portion includes a pattern of spaces formed within the launching member. The flexible portion is configured to bend more easily than adjacent less flexible portions of the launching member due to the load during the firing stroke. The flexible portion is made of the same material as the adjacent less flexible portions.

[0189] Example 23 - Channel retainer for use with surgical instrument. The channel retainer is positionable between the handle and end effector of the surgical instrument. The channel retainer comprises a proximal end, a distal end, a plastic body extending from the proximal end to the distal end, a first metal substrate positioned within the plastic body, and a second metal substrate positioned within the plastic body. The first metal substrate includes a lateral flange. The second metal substrate includes an opening. The lateral flange is positioned within the opening to operably connect the first and second metal substrates within the plastic body.

[0190] Example 24 - The channel holder according to Example 23, wherein the first metal substrate is positioned at the proximal end of the channel holder, and the proximal end of the channel holder is configured to be attached to the handle of a surgical instrument.

[0191] Example 25 - The channel holder according to Example 23 or 24, wherein the plastic body comprises an alignment notch, and the first metal substrate comprises another lateral flange embedded in the plastic body proximal to the alignment notch.

[0192] Example 26 - A channel holder according to Example 23, 24, or 25, wherein at least one of the first metal substrate and the second metal substrate includes a molded metal component.

[0193] Example 27 - The channel holder according to Example 23, 24, 25, or 26, wherein the plastic body is printed on a first metal substrate and a second metal substrate.

[0194] Example 28 - A channel holder according to Example 23, 24, 25, 26, or 27, wherein the plastic body comprises one of the group consisting of a keying feature, an alignment feature, and a connecting feature for connection to a surgical instrument.

[0195] Example 29 - A channel holder according to Example 23, 24, 25, 26, 27, or 28, wherein at least one of the first metal substrate and the second metal substrate includes a flexible circuit board.

[0196] Example 30 - Channel retainer for use with surgical instrument. The channel retainer comprises a proximal end, a distal end, a first metal substrate, a second metal substrate connected to the first metal substrate, and a plastic portion extending from the proximal end to the distal end. The plastic portion is constructed around the first and second metal substrates.

[0197] Example 31 - The channel holder according to Example 30, wherein the first metal substrate comprises a flange embedded in the alignment portion of the plastic portion, and the alignment portion is configured to attach the plastic portion to a surgical instrument.

[0198] Example 32 - The channel holder according to Example 30 or 31, wherein the plastic portion comprises an alignment notch, and the first metal substrate comprises a lateral flange embedded in the plastic portion proximal to the alignment notch.

[0199] Example 33 - A channel holder according to Example 30, 31, or 32, wherein at least one of the first metal substrate and the second metal substrate includes a molded metal component.

[0200] Example 34 - The channel holder according to Example 30, 31, 32, or 33, wherein the plastic portion is printed on a first metal substrate and a second metal substrate.

[0201] Example 35 - A channel holder according to Example 30, 31, 32, 33, or 34, wherein the plastic portion comprises one of the group consisting of a keying feature, an alignment feature, and a connecting feature for connection to a surgical instrument.

[0202] Example 36 - A channel holder according to Example 30, 31, 32, 33, 34 or 35, wherein at least one of the first metal substrate and the second metal substrate includes a flexible circuit board.

[0203] Example 37 - End effector component for use with a surgical stapling device. The end effector component comprises a plastic body having an alignment feature. The end effector component further comprises a first metal substrate at least partially surrounded by the plastic body. The end effector component further comprises a second metal substrate at least partially surrounded by the plastic body. The first and second metal substrates have substrate connecting features embedded within the plastic body.

[0204] Example 38 - An end effector component according to Example 37, wherein the first metal substrate comprises a lateral flange, the second metal substrate comprises an opening, the lateral flange is positioned within the opening, and is surrounded by a plastic body.

[0205] Example 39 - An end effector component according to Example 37 or 38, wherein the alignment feature portion comprises notches at the proximal and distal ends of the plastic body, and the notches facilitate the attachment and alignment of the end effector component to the handle and end effector of a surgical staple fastening device.

[0206] Example 40 - The end effector component according to Example 37, 38, or 39, wherein the end effector component comprises an elongated channel configured to receive a staple cartridge.

[0207] Example 41 - An end effector component according to Example 37, 38, 39, or 40, wherein at least one of the first metal substrate and the second metal substrate includes a flexible circuit substrate.

[0208] Example 42 - An end effector component according to Example 37, 38, 39, 40, or 41, wherein the plastic body has an internal void, and the internal void is completely surrounded by the plastic body.

[0209] Example 43 - An end effector component according to Example 37, 38, 39, 40, 41, or 42, wherein the plastic body has an undercut.

[0210] Many of the surgical instrument systems described herein are driven by electric motors. However, the surgical instrument systems described herein may be driven in any preferred manner. In various cases, the surgical instrument systems described herein may be driven, for example, by a manually operated trigger. In certain cases, the motors disclosed herein may comprise one or more parts of a robotically controlled system. Furthermore, any of the end effectors and / or tool assemblies disclosed herein may be used in conjunction with a robotic surgical instrument system. For example, U.S. Patent Application No. 13 / 118,241, titled “SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS” (now U.S. Patent No. 9,072,535) discloses in more detail several embodiments of a robotic surgical instrument system.

[0211] While the surgical instrument systems described herein have been described in relation to the arrangement and deformation of staples, the embodiments described herein are not limited thereto. For example, various embodiments may involve the arrangement of fasteners other than staples, such as clamps or tacks. Furthermore, various embodiments may utilize any suitable means for sealing tissue. For example, end effectors according to various embodiments may include electrodes configured to heat and seal tissue. Similarly, for example, end effectors according to certain embodiments may apply vibrational energy to seal tissue.

[0212] The entirety of the following disclosure is incorporated herein by reference. - U.S. Patent No. 5,403,312, issued on April 4, 1995, with the title of the invention "ELECTROSURGICAL HEMOSTATIC DEVICE", - U.S. Patent No. 7,000,818, issued on February 21, 2006, with the title of the invention "SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS", - U.S. Patent No. 7,422,139, issued on September 9, 2008, with the title of the invention "MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK", - U.S. Patent No. 7,464,849, issued on December 16, 2008, with the title of the invention "ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS", - U.S. Patent No. 7,670,334, issued on March 2, 2010, with the title of the invention "SURGICAL INSTRUMENT HAVING AN ARTICULATING END EFFECTOR", - U.S. Patent No. 7,753,245, issued on July 13, 2010, with the title of the invention "SURGICAL STAPLING INSTRUMENTS", - U.S. Patent No. 8,393,514, issued on March 12, 2013, with the title of the invention "SELECTIVELY ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE", - U.S. Patent Application No. 11 / 343,803, Title of Invention: "SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES" (currently U.S. Patent No. 7,845,537), - U.S. Patent Application No. 12 / 031,573, filed February 14, 2008, Title of Invention: "SURGICAL CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES", - U.S. Patent Application No. 12 / 031,873, filed on February 15, 2008, title of invention: "END EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT" (currently U.S. Patent No. 7,980,443), - U.S. Patent Application No. 12 / 235,782, Title of Invention: "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT" (currently U.S. Patent No. 8,210,411), - U.S. Patent Application No. 12 / 249,117, Title of Invention: "POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM" (currently U.S. Patent No. 8,608,045), -U.S. Patent Application No. 12 / 647,100, filed on December 24, 2009, title of invention: "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY" (currently U.S. Patent No. 8,220,688), - U.S. Patent Application No. 12 / 893,461, filed September 29, 2012, title of invention "STAPLE CARTRIDGE" (currently U.S. Patent No. 8,733,613), - U.S. Patent Application No. 13 / 036,647, filed on February 28, 2011, title of invention "SURGICAL STAPLING INSTRUMENT" (currently U.S. Patent No. 8,561,870), - U.S. Patent Application No. 13 / 118,241, Title of Invention: "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS" (currently U.S. Patent No. 9,072,535), - U.S. Patent Application No. 13 / 524,049, filed June 15, 2012, title of invention "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE" (currently U.S. Patent No. 9,101,358), - U.S. Patent Application No. 13 / 800,025, filed March 13, 2013, title of invention "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM" (currently U.S. Patent No. 9,345,481), U.S. Patent Application No. 13 / 800,067, filed on March 13, 2013, title of invention: "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM" (currently U.S. Patent Publication No. 2014 / 0263552), - U.S. Patent Application Publication No. 2007 / 0175955, filed on January 31, 2006, title of invention "SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM", and - U.S. Patent Application Publication No. 2010 / 0264194, filed on April 22, 2010, with the title of the invention "SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR" (currently U.S. Patent No. 8,308,040).

[0213] While various devices have been described herein in conjunction with specific embodiments, modifications and changes may be made to those embodiments. Specific features, structures, or properties may be combined in any preferred manner in one or more embodiments. Thus, specific features, structures, or properties illustrated or described in relation to one embodiment may be combined in whole or in part with features, structures, or properties of one or more other embodiments without limitation. Also, while materials are disclosed in relation to specific components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, in order to perform a given function. The foregoing description and the following claims are intended to encompass all such modifications and variations.

[0214] The devices disclosed herein may be designed to be discarded after a single use or to be designed for multiple uses. However, in either case, the devices may be reconditioned for reuse after at least one use. Reconditioning may include, but is not limited to, any combination of disassembly of the device, subsequent cleaning or replacement of specific parts of the device, and subsequent reassembly of the device. Specifically, a reconditioning facility and / or surgical team may disassemble the device, clean and / or replace specific parts of the device, and then reassemble the device for subsequent use. Those skilled in the art will understand that reconditioning of a device may utilize a variety of techniques for disassembly, cleaning / replacement, and reassembly. The use of such techniques and the resulting reconditioned devices are all within the scope of this application.

[0215] The apparatus disclosed herein may be treated before surgery. First, new or used instruments are obtained and may be cleaned as necessary. Next, the instruments may be sterilized. In one sterilization technique, the instruments are placed in a closed and sealed container, such as a plastic bag or a TYVEK bag. Next, the container and instruments may be placed in a radiation field that can penetrate the container, such as gamma rays, X-rays, and / or high-energy electrons. The radiation can kill bacteria on the instruments and inside the container. After this, the sterilized instruments may be stored in a sterile container. The sealed container can keep the instruments sterile until opened in a medical facility. The apparatus may also be sterilized using any other technique known in the art, including but not limited to beta rays, gamma rays, ethylene oxide, hydrogen peroxide plasma, and / or steam.

[0216] While the present invention has been described as having a representative design, the present invention may be further modified within the spirit and scope of this disclosure. Accordingly, this application is intended to cover any variations, uses, or adaptations of the present invention using its general principles.

[0217] Any patents, publications, or other disclosures incorporated herein by reference, in whole or in part, shall be incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, views, or other disclosures contained herein. Disclosures expressly contained herein, both in themselves and to the extent necessary, shall supersede any conflicting statements incorporated herein by reference. Any material, or any part thereof, that is referred to as being incorporated herein by reference but conflicts with current definitions, views, or other disclosures contained herein shall be incorporated herein only to the extent that there is no conflict between the incorporated material and the current disclosures.

[0218] [Implementation Method] (1) A launching member for use with a surgical instrument comprising an anvil and an elongated channel configured to receive a staple cartridge, wherein the launching member is The main body is configured to be driven via a firing stroke, A first cam member extends laterally from the main body portion and is configured to engage with the anvil and cam during the firing stroke, A second cam member extends laterally from the main body portion and is configured to engage with the elongated channel and cam during the firing stroke, A launching member comprising: a grid portion including a pattern of spaces formed within the launching member, wherein the grid portion is configured to bend more easily than adjacent portions of the launching member due to the load during the launching stroke. (2) The launching member according to Embodiment 1, wherein the grid portion is positioned between the first cam member and the second cam member. (3) The launch member according to Embodiment 2, further comprising a longitudinal slot extending longitudinally through the launch member, wherein the longitudinal slot is configured to divide the grid portion into a first portion on the first side of the longitudinal slot and a second portion on the second side of the longitudinal slot, and the grid portion is deflected in opposite directions on both sides of the longitudinal slot. (4) The launching member according to Embodiment 3, wherein the pattern of the space comprises a first plurality of slots in the first portion and a second plurality of slots in the second portion. (5) The launching member according to Embodiment 4, wherein the first plurality of slots are oriented in a first direction and the second plurality of slots are oriented in a second direction opposite to the first direction.

[0219] (6) The launching member according to Embodiment 5, wherein the first plurality of slots are parallel to each other and the second plurality of slots are parallel to each other. (7) The launching member according to Embodiment 1, wherein the grid portion connects at least a part of the first cam member to the main body portion. (8) The launching member according to embodiment 7, wherein the pattern of the space defines a plurality of arc-shaped bars connecting the first cam member and the main body portion. (9) The launching member according to embodiment 8, wherein the plurality of arc-shaped bars are arranged in an array. (10) The launching member according to embodiment 7, wherein the spatial pattern includes an array of intersecting oblique slots.

[0220] (11) The launching member according to Embodiment 7, wherein the grid portion has lower rigidity than the first cam member and the main body portion. (12) End effector, Anvil and, An elongated channel configured to receive a staple cartridge, A launching member, The main body and A first cam member extends laterally from the main body portion and is configured to cam-engage with the anvil during the firing stroke of the firing member, A second cam member extends laterally from the main body portion and is configured to engage with the elongated channel and cam during the firing stroke, An end effector comprising a launching member, the launching member comprising a flexible portion positioned between the first cam member and the main body portion, wherein the flexible portion comprises a three-dimensional grid having an array of cavities. (13) The end effector according to embodiment 12, wherein the array of cavities defines a plurality of arc-shaped bars. (14) The end effector according to embodiment 13, wherein the flexible portion has a first rigidity, the main body portion and the first cam member have a second rigidity, and the first rigidity and the second rigidity are different. (15) A launching member for use with a surgical instrument having a first jaw and a second jaw, wherein the launching member is A main body portion configured to move longitudinally through a firing stroke, A first cam member extends laterally from the main body portion and is configured to cam-engage with the first jaw portion during the firing stroke, A second cam member extends laterally from the main body portion and is configured to cam-engage with the second jaw portion during the firing stroke, A launching member comprising a low-density portion including a flexible grid configured to bend more easily than adjacent portions of the launching member due to the load during the launching stroke.

[0221] (16) The launching member according to Embodiment 15, wherein the flexible grid is deflected by a first amount when the first cam member is under load, and the main body portion adjacent to the flexible grid is deflected by a second amount when the first cam member is under load, with the first amount being greater than the second amount. (17) The launching member according to embodiment 15, wherein the main body portion has a first rigidity, and the flexible grid has a second rigidity, and the first rigidity and the second rigidity are different. (18) The launching member according to embodiment 15, wherein the flexible grid comprises a plurality of slots arranged in a pattern and defined within the main body portion. (19) The launching member according to embodiment 15, wherein the main body portion includes a first filling density, the low-density portion includes a second filling density, and the first filling density and the second filling density are different. (20) The launch member according to embodiment 15, further comprising a longitudinal slot extending longitudinally through the launch member, wherein the longitudinal slot branches the flexible grid into a first portion on the first side of the longitudinal slot and a second portion on the second side of the longitudinal slot.

[0222] (21) The launching member according to embodiment 20, wherein the first portion comprises a plurality of slots oriented in a first direction, and the second portion comprises a plurality of slots oriented in a second direction opposite to the first direction. (22) A launching member for use with a surgical instrument comprising an anvil and an elongated channel configured to receive a staple cartridge, wherein the launching member is The main body is configured to be driven via a firing stroke, A first cam member extends laterally from the main body portion and is configured to engage with the anvil and cam during the firing stroke, A second cam member extends laterally from the main body portion and is configured to engage with the elongated channel and cam during the firing stroke, A launching member comprising: a flexible portion including a pattern of spaces formed within the launching member, wherein the flexible portion is configured to bend more easily than adjacent less flexible portions of the launching member due to the load during the launching stroke, and the flexible portion is made of the same material as the adjacent less flexible portions.

Claims

1. A launching member for use with a surgical instrument comprising an anvil and an elongated channel configured to receive a staple cartridge, wherein the launching member is The main body is configured to be driven via a firing stroke, A first cam member extends laterally from the main body portion and is configured to engage with the anvil and cam during the firing stroke, A second cam member extends laterally from the main body portion and is configured to engage with the elongated channel and cam during the firing stroke, A grid portion including a pattern of spaces formed within the launching member, wherein the grid portion is configured to bend more easily than adjacent portions of the launching member due to the load during the launching stroke, The grid portion is positioned midway between the first cam member and the second cam member. A launching member further comprising a longitudinal slot extending longitudinally through the launching member, wherein the longitudinal slot is configured to divide the grid portion into a first portion on the first side of the longitudinal slot and a second portion on the second side of the longitudinal slot, and the grid portion is deflected in opposite directions on both sides of the longitudinal slot.

2. The launching member according to claim 1, wherein the pattern of the space comprises a first plurality of slots in the first portion and a second plurality of slots in the second portion.

3. The launching member according to claim 2, wherein the first plurality of slots are oriented in a first direction, and the second plurality of slots are oriented in a second direction opposite to the first direction.

4. The launching member according to claim 3, wherein the first plurality of slots are parallel to each other, and the second plurality of slots are parallel to each other.

5. A launching member for use with a surgical instrument comprising an anvil and an elongated channel configured to receive a staple cartridge, wherein the launching member is The main body is configured to be driven via a firing stroke, A first cam member extends laterally from the main body portion and is configured to engage with the anvil and cam during the firing stroke, A second cam member extends laterally from the main body portion and is configured to engage with the elongated channel and cam during the firing stroke, A grid portion including a pattern of spaces formed within the launching member, wherein the grid portion is configured to bend more easily than adjacent portions of the launching member due to the load during the launching stroke, A launching member in which the grid portion connects at least a part of the first cam member to the main body portion.

6. The launching member according to claim 5, wherein the pattern of the space defines a plurality of arc-shaped bars connecting the first cam member and the main body portion.

7. The launching member according to claim 6, wherein the plurality of arc-shaped bars are arranged in an array.

8. The launching member according to claim 5, wherein the pattern of the space includes an array of intersecting diagonal slots.

9. The launching member according to claim 5, wherein the grid portion has lower rigidity than the first cam member and the main body portion.

Images