Barbed Suture Cutting Apparatus with Multi-Axis Control
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Solution Overview
Problem
Current methods for cutting barbs on sutures lack precision, reliability, and versatility, making it difficult to vary barb size, location, and depth, and are not suitable for different types of tissue repair and filament materials.
Innovation Solution
An apparatus with directional feed motors and a cutting assembly that allows independent motion of cutters along vertical, longitudinal, and perpendicular directions, combined with a tensioner and collet system for precise barb formation and filament tensioning, enabling the cutting of barbs in various lengths, depths, and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a random configuration of barbs is used to achieve superior wound holding, then wound holding capability is improved, but the complexity of controlling barb configuration and the difficulty of precise manufacturing increase
Solution Approach 1:
The cutting assembly incorporates movable components that allow dynamic adjustment of cutting parameters including barb angle, depth, and spacing. The system can transition between random and controlled configurations based on surgical requirements, resolving the contradiction by making the configuration adaptable rather than fixed.
Solution Approach 2:
The apparatus enables changing of multiple parameters simultaneously (barb angle, depth, spacing, density) to optimize wound holding while maintaining manufacturability. By providing independent control over each parameter, the system achieves superior wound holding without excessive manufacturing complexity.
2Strength
If multiple barbs are cut on a thin suture for better tissue anchoring, then tissue anchoring is improved, but the risk of filament damage and manufacturing complexity increase
Solution Approach 1:
The cutting assembly is designed as a universal system that can accommodate different filament diameters and material types while maintaining precise control over barb formation. The same apparatus can produce barbs on thin sutures for delicate tissue or thicker sutures for stronger anchoring needs, reducing overall system complexity.
Solution Approach 2:
The system allows local optimization of barb characteristics by independently controlling cutting parameters at different locations along the filament. This enables dense barb configurations in areas requiring strong anchoring while maintaining simpler configurations in other areas, balancing tissue anchoring needs with apparatus complexity.
3Adaptability or versatility
If barbs are cut at various angles and positions for different tissue repair needs, then adaptability is improved, but the complexity of the cutting assembly and manufacturing process increase
Solution Approach 1:
The cutting assembly is divided into modular components that can be independently adjusted and configured. Each module handles specific aspects of barb formation (angle control, depth control, positioning), allowing the system to achieve high adaptability through simple, interchangeable modules rather than a complex monolithic structure.
Data Source
AI summary
An apparatus for cutting barbs into a suture having a filament supply. The apparatus also has an in-feed collet for holding one end of a filament threaded therethrough. Further the apparatus has an out-feed collet for holding a second end of a filament threaded therethrough. Additionally, the apparatus has a holder positioned between said in-feed and out-feed collets for holding a filament suspended between the in-feed and out-feed collets. The apparatus also has a cutting assembly for cutting barbs in the filament tensioned between the in-feed and out-feed collets.