Additive-Manufactured Cutting Insert Frame for Lower-Cost Blades
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Solution Overview
Problem
Manufacturing high-quality replacement blades for surgical instruments is costly, and existing methods do not effectively address the need for cost reduction without compromising quality or capability.
Innovation Solution
A cutting instrument design featuring blades with pockets that receive cutting inserts in a green state, which are permanently fixed after heat treatment, allowing for various cutting edges and shapes, and fabricated using additive manufacturing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to produce replacement blades, then high quality and durability are achieved, but manufacturing costs increase significantly
Solution Approach 1:
The blade is segmented into a frame structure with multiple pockets that can independently receive different cutting inserts. This allows the blade body to be manufactured once and reused, while only the cutting inserts need to be replaced or customized, significantly reducing manufacturing costs while maintaining blade quality
Solution Approach 2:
The blade frame is designed with universal pockets that can accommodate various types of cutting inserts with different geometries and materials. The standardized pocket design allows a single frame to perform multiple cutting functions by simply changing the inserts, reducing the need to manufacture multiple specialized blades
2Ease of manufacture
If additive manufacturing is used to create the blade frame, then manufacturing cost and complexity are reduced, but the precision of fitting cutting inserts may be compromised
Solution Approach 1:
The cutting inserts are designed with engagement portions that are precisely machined to fit within the additive-manufactured pockets. By pre-precising the critical mating surfaces on the inserts rather than on the pockets, the system achieves high assembly precision while maintaining the cost advantages of additive manufacturing for the frame
Solution Approach 2:
The design incorporates clearance parameters and tolerance zones that account for the inherent variability of additive manufacturing. By optimizing the dimensional parameters of the pockets and engagement portions, the system achieves reliable assembly and functional precision despite the subtractive vs. additive manufacturing process differences
3Adaptability or versatility
If the blade design accommodates various cutting insert shapes and configurations, then versatility is improved, but the complexity of the blade structure increases
Solution Approach 1:
The blade frame employs a universal pocket design that can accommodate multiple types of cutting inserts with different shapes, sizes, and materials. The standardized interface and engagement mechanism allow the same frame structure to support diverse cutting configurations, achieving versatility without proportionally increasing structural complexity
Solution Approach 2:
The blade structure is segmented into a modular frame with discrete pockets, allowing each pocket to independently hold different cutting inserts. This segmentation enables the frame to adapt to various cutting requirements while maintaining a relatively simple overall structure, as the complexity is localized to the insert-level rather than requiring complex frame variations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces manufacturing costs while maintaining blade quality and versatility, enabling cost-effective production of durable and efficient cutting instruments.
Implementation Method 1
During heat treatment, the walls of the pocket shrink around a portion of the cutting insert such that a cutting edge of the cutting insert extends beyond the walls of the pocket
Data Source
Figure 1
Figure 2A~2B
Figure 3~4A
AI summary
A cutting instrument including an insert and a frame having sidewalls that extend from a base and define a slot. The slot is configured to receive a portion of the insert such that an edge of the insert extends beyond the frame. The sidewalls are configured to shrink around a portion of the insert such that an edge of the insert extends beyond the frame. Additionally, a method for fabricating a cutting instrument including depositing layers of metal powder onto a base and selectively binding the deposited layers of the metal powder onto the base to form a frame attached to the base. Next, placing an insert within the frame such that a portion of the insert extends beyond the frame and the combination of the base, the frame, and the insert forms an in-process assembly.