A method of manufacturing an
endodontic instrument using an electrochemical (ECG)
grinding process. An instrument blank is formed from stock material, and an
electric current is applied between an
electrically conductive grinding wheel, acting as a
cathode, and the instrument blank, acting as an
anode. A continuous
stream of
electrolyte fluid, a conductive
aqueous solution, is applied at an interface between the
grinding wheel and the instrument blank, the
electrolyte fluid having an associated volume and pressure. The instrument blank is advanced past the
electrically conductive grinding wheel to remove material from the instrument blank to form at least one
cutting flute. The
electric current applied between the
grinding wheel and the instrument blank is reduced, and the instrument blank is advanced past the
grinding wheel again to form a finish surface, e.g., a sharp
cutting edge, on the at least one
cutting flute. The process may be repeated to form an
endodontic instrument having a plurality of cutting flutes. The cutting flutes may be helically or non-helically shaped. The instrument blank is formed of an
electrically conductive material, such as
nickel titanium or stainless steel. In one variation, the
electric current may be eliminated entirely during the final finishing pass. The volume and pressure of the
electrolyte may be varied. Endodontic instruments formed by the method of the present invention are also disclosed.