Curved Surgical Stapler Frame Stamping for Tight-Tolerance Assembly
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Solution Overview
Problem
Conventional manufacturing processes for surgical stapler frames are time-consuming, expensive, and inefficient, particularly when machining from a single solid block of material, which can lead to waste and inadequate tolerances in critical components.
Innovation Solution
The use of alternative frame designs and manufacturing methods, such as stamping, metal injection molding, and additive manufacturing, allows for the efficient, cost-effective, and robust production of surgical stapler frames with tighter tolerances in critical areas, enabling improved performance and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional machining from a single solid block is used, then structural integrity is maintained, but production time and cost increase significantly
Solution Approach 1:
The frame is divided into multiple separate components (first portion, second portion, third portion) that are manufactured independently using stamping processes, then assembled together. This segmentation allows each component to be produced efficiently through stamping rather than time-consuming solid block machining, directly reducing production time while maintaining structural integrity through proper coupling mechanisms.
Solution Approach 2:
Multiple stamped frame portions are combined through coupling mechanisms (fasteners, welding, or other joining methods) to form the complete frame assembly. This merging of separately manufactured components achieves both the productivity benefits of stamping and the structural requirements of the complete frame, resolving the contradiction between manufacturing efficiency and structural integrity.
2Ease of manufacture
If conventional machining is used, then material strength is preserved, but manufacturing cost increases
Solution Approach 1:
The frame structure is segmented into multiple portions that can be manufactured using cost-effective stamping processes. By dividing the frame into manageable sections (first portion, second portion, third portion), each can be produced efficiently through stamping rather than expensive solid block machining, reducing overall manufacturing cost while maintaining necessary strength through proper design of coupling interfaces.
Solution Approach 2:
The frame assembly becomes a composite structure combining multiple stamped metal portions joined through coupling mechanisms. This composite approach allows the use of cost-effective stamping processes for each component while the combined assembly achieves the required overall strength and structural performance, resolving the contradiction between manufacturing cost and frame strength.
3Productivity
If stamping is used for frame portions, then production efficiency increases, but tolerance precision may be insufficient
Solution Approach 1:
The frame is segmented into multiple portions manufactured by stamping, with coupling mechanisms designed to accommodate and compensate for stamping tolerances. By properly designing the coupling interfaces between stamped portions, the system maintains adequate precision for critical functions while benefiting from the high production efficiency of stamping processes.
Solution Approach 2:
Different portions of the frame may employ different manufacturing approaches or stamping techniques tailored to their specific functional requirements. Critical areas requiring higher precision can be manufactured with tighter tolerances or post-processing, while non-critical areas use standard stamping tolerances, optimizing the balance between production efficiency and manufacturing precision across the entire frame assembly.
Data Source
AI summary
A method is used to manufacture a frame of a curved surgical stapler. The method includes manufacturing a first portion of the frame of the curved surgical stapler separate from the first portion. The first portion includes a first curvilinear portion of an end effector and a first alignment feature. The method also includes manufacturing a second portion of the frame of the curved surgical stapler. The second portion includes a second alignment feature. The method also includes manufacturing a third portion of the frame of the curved surgical stapler separate from either of the first or second portions. The third portion includes a C-shaped track. The method also includes aligning the first and second portions portion with the second portion by aligning the first and second alignment features. The method also includes coupling the first and second portions of the frame of the curved surgical stapler together.