Articulable Surgical Tools with Additive Manufacturing
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Solution Overview
Problem
Current surgical instruments for minimally invasive procedures, such as microdiscectomy, lack dexterity and vision, often causing inadvertent damage to tissues due to their rigidity and limited flexibility, and are costly and complex to manufacture, with robotic systems being limited in practical application and cost.
Innovation Solution
A system comprising a cannula with articulable and rotatable tools produced using additive manufacturing, allowing for improved dexterity and vision within confined spaces, featuring a tubular body with multiple ports for tool insertion and articulation, and working elements that can be rotated and secured to a shaft for precise task performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid surgical tools are used, then structural strength is maintained, but dexterity and flexibility are reduced causing tissue damage
Solution Approach 1:
The surgical tool is divided into multiple segments or sections that can articulate relative to each other. The shaft includes multiple articulation points that allow the distal end to bend and rotate independently, enabling the tool to navigate complex anatomical pathways while maintaining structural integrity through the segmented design.
Solution Approach 2:
The tool transitions from a static rigid structure to a dynamic articulated structure. The articulation mechanism allows the tool to change its configuration during operation, adapting to the surgical field requirements while maintaining sufficient rigidity for precise manipulation and tissue interaction.
2Ease of operation
If flexible tools with large radius of curvature are used, then flexibility is improved, but working space requirements increase
Solution Approach 1:
By segmenting the tool into multiple articulated sections, the minimum bending radius is significantly reduced compared to a single flexible element. Each segment can articulate independently, allowing the tool to navigate tight spaces and sharp angles that would be impossible for tools with large radius of curvature.
Solution Approach 2:
The articulation joints are designed to enable sharp changes in direction with small radius of curvature. The mechanical design of the articulation points allows for tight bending capabilities, enabling the tool to access confined anatomical spaces that rigid or large-radius flexible tools cannot reach.
3Length of moving object
If small diameter tools are used, then access to confined spaces is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The tool employs a flexible shaft construction that can be manufactured as a continuous or minimally segmented structure, reducing assembly complexity. The flexible shaft allows the tool to maintain small diameter while providing necessary articulation through material flexibility rather than complex mechanical joints, simplifying manufacturing.
Solution Approach 2:
The surgical tool is designed as a disposable single-use instrument, eliminating the need for complex sterilization and reprocessing systems. This disposable design allows for optimized manufacturing processes that prioritize performance and safety over long-term durability, reducing overall system complexity and cost.
4Measurement precision
If robotic surgical systems are used, then precision is improved, but system size and cost increase
Solution Approach 1:
The articulated tool provides inherent dexterity and adaptability through its mechanical design, eliminating the need for complex robotic control systems. The tool can be manually manipulated to achieve precise positioning and orientation, providing surgeon control without requiring large robotic arms, sensors, and control algorithms.
Solution Approach 2:
The articulated tool design can be adapted for multiple surgical applications and configurations, providing versatility without requiring separate specialized robotic systems for each procedure. The same basic articulated structure can perform various surgical tasks through different working elements and manipulation techniques.
Data Source
AI summary
Systems and methods for performing a surgical procedure within a body cavity. The systems include a cannula having a tubular body with ports located at first and second ends thereof, wherein the second end is configured to be inserted into the cavity. The systems further include one or more tools configured to be inserted into the cannula through the ports on the first end, extend through the body of the cannula, and protrude from the ports on the second end. The tools each include a shaft with a working element on a distal end of the shaft, at least portions of which are capable of articulation relative to the shaft, rotation relative to the cannula, and are configured to perform tasks in the cavity. The working element may be produced with an additive manufacturing technique.