Laser Drilling Surgical Needles with Percussive Pulsed Beam
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Solution Overview
Problem
Conventional laser drilling systems for surgical needles face challenges such as asymmetrical bore hole geometry, frequent quality assurance inspections, downtime for adjustments, and difficulty in drilling various needle sizes, especially medium to large diameters, due to limitations in beam power and quality, and the need for ink coatings.
Innovation Solution
A novel laser drilling system utilizing a low power fiber Nd-YAG seed laser with a modulated and amplified high quality beam, directed through electro-optical components for precise percussive drilling, enabling high quality blind bore holes in surgical needles with minimal downtime and easy adjustment between different needle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser drilling systems are used to drill blind bore holes in surgical needles, then high speed drilling capabilities are achieved, but the bore holes tend to have asymmetrical configuration and require frequent quality assurance inspections
Solution Approach 1:
The patent applies periodic pulsed laser action to drill bore holes, using a series of controlled laser pulses rather than continuous drilling. This periodic action allows molten and vaporized material to be ejected between pulses, creating more symmetrical bore holes while maintaining high drilling speed. The pulse timing and duration are optimized to achieve both productivity and precision.
2Adaptability or versatility
If conventional laser drilling systems are used for medium to large diameter needles, then drilling capability is achieved, but ink coating is required which adds complexity and cost
Solution Approach 1:
The patent changes the laser beam parameters including wavelength, pulse duration, and power density to enable direct drilling of medium to large diameter needles without ink coating. By optimizing these parameters, the laser energy is effectively coupled to the needle material, achieving acceptable bore holes through parameter optimization rather than requiring additional ink coating processes.
3Adaptability or versatility
If laser beam parameters are varied to drill different needle sizes, then versatility is improved, but recast and remelt deficiencies occur
Solution Approach 1:
The patent employs dynamic adjustment of laser parameters during the drilling process, adapting pulse duration, power, and frequency based on the specific needle size and material properties. This dynamic control prevents excessive energy input that would cause recast and remelt, while still achieving versatile drilling capability across different needle sizes. The system responds in real-time to maintain precision.
4Manufacturing precision
If frequent quality assurance inspections are conducted to monitor bore hole geometry, then manufacturing precision is maintained, but production downtime increases
Solution Approach 1:
The patent implements feedback control mechanisms that continuously monitor drilling parameters and bore hole quality, automatically adjusting laser settings to maintain conformance to specifications. This closed-loop feedback system reduces the need for frequent manual quality assurance inspections, maintaining manufacturing precision while minimizing production downtime through automated real-time corrections.
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
The system achieves high quality, symmetrical bore holes with reduced recast and remelt, allowing for efficient drilling of various needle sizes without ink coatings, enhancing production efficiency and reducing downtime for adjustments.
Implementation Method 1
the laser drilling process is a percussive drilling process wherein a laser beam is chopped into a series of pulses
Implementation Method 2
the drilling process produces molten and vaporized metal that is ejected out of the bore hole during the process
Implementation Method 3
it is typically necessary to apply an ink coating to the proximal end of the needle. This ink coating allows for more effective energy absorption and beam coupling
Data Source
AI summary
Novel laser drilling systems are disclosed. The laser drilling systems are useful for drilling bore holes in medical devices, especially blind bore holes in surgical needles. The laser systems use a low power fiber seed laser to produce a high quality laser beam that is modulated and amplified, and which has precise characteristics to produce precision drilled holes.