MIM Surgical Stapler Anvil for Precise Staple Pocket Alignment
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Solution Overview
Problem
Existing circular surgical staplers lack a cost-effective and reliable method for manufacturing anvils that ensure precise alignment and deformation of staples, leading to inconsistent staple formation and potential leaks at anastomosis sites.
Innovation Solution
The development of anvils manufactured using metal injection molding (MIM) with subsequent coining or electrochemical machining of staple forming pockets, allowing for precise deformation of staples and improved surface properties, combined with a shank and head assembly that ensures consistent angular alignment with the stapling head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for anvils, then manufacturing cost is reduced, but manufacturing precision and consistency of staple formation deteriorate
Solution Approach 1:
The patent applies metal injection molding (MIM) technology to manufacture the anvil, which involves changing the manufacturing parameters and process methodology. MIM allows for precise control of material properties and geometric features during the molding process, enabling consistent staple formation pockets with high precision while maintaining cost-effectiveness through automated manufacturing and material efficiency.
2Reliability
If simple manufacturing processes are used for anvils, then manufacturing complexity is reduced, but reliability of staple deformation deteriorates
Solution Approach 1:
The patent employs metal injection molding with controlled material parameters and processing conditions to ensure reliable staple deformation. The MIM process allows for precise control of density, surface finish, and geometric accuracy of the staple forming pockets, which directly impacts the reliability of staple deformation while the automated nature of MIM keeps the overall manufacturing process manageable.
3Manufacturing precision
If conventional anvil manufacturing is used, then manufacturing time is reduced, but consistency of staple formation deteriorates
Solution Approach 1:
The metal injection molding process incorporates preliminary action by pre-forming the anvil with precisely controlled staple formation pockets during the molding stage itself. This eliminates the need for subsequent extensive machining or finishing operations, as the critical geometric features are established with high consistency during the initial molding process, reducing both time and improving consistency.
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
This approach results in consistently formed staples with improved surface properties, reducing the risk of leaks and ensuring precise alignment, thereby enhancing the reliability and effectiveness of anastomosis procedures.
Implementation Method 1
forming the head of a surgical circular stapler using a metal injection molding process
Implementation Method 2
a portion of at least one staple forming pocket of the annular array of staple forming pockets is coined or electrochemical machined
Implementation Method 3
a portion of at least one staple forming pocket of the annular array of staple forming pockets is coined or electrochemical machined
Data Source
AI summary
A method is used to manufacture an anvil of a surgical circular stapler. The anvil includes a head and a shank extending proximally from the head. The method includes forming the head of a surgical circular stapler using a metal injection molding process. The method also includes forming an annular array of staple forming pockets in the head. The method also includes machining the shank of the surgical circular stapler. The method also includes coupling together the head and the shank of the surgical circular stapler that were separately manufactured.