Ophthalmologic Device Head Manufacturing via Two-Step Profile Formation
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Solution Overview
Problem
Conventional methods for manufacturing micro instruments, such as those used in medical devices, face challenges in achieving precision and cost-effectiveness due to geometric defects caused by misalignment and variation in straightness, leading to imbalanced actuation and undesirable motion during tissue grasping or cutting.
Innovation Solution
A two-step manufacturing method involving forming a first profile in a sheet of material in a first orientation plane and a second profile in a second orientation plane, allowing for the complete formation of device heads with arms and a rod, which are tolerant to equipment misalignment and eliminate the need for subsequent bending steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to manufacture micro instruments, then the manufacturing process can be completed, but geometric defects occur due to misalignment and variation in straightness
Solution Approach 1:
The manufacturing process is segmented into two independent profile-forming operations: a first profile is formed in a first orientation plane, and a second profile is formed in a second orientation plane. This segmentation allows each profile to be formed independently without compounding misalignment errors, thereby improving geometric precision and actuation consistency.
2Ease of manufacture
If multiple machining operations are performed to form the rod and grasping surfaces, then the parts can be fabricated, but machining time and costs increase
Solution Approach 1:
The formation of both profiles (side profile and top profile) is merged into a coordinated two-step process that completes the device head in fewer operations. The first profile formation and second profile formation are combined to define the complete three-dimensional geometry, reducing total machining time while maintaining manufacturability.
3Ease of operation
If the arms are bent in a subsequent operation to achieve the biased outward position, then the relaxed position can be achieved, but additional geometric defects may occur
Solution Approach 1:
The arms are formed in their biased outward relaxed position during the initial profile formation steps, rather than requiring subsequent bending operations. The first profile and second profile are designed to directly create the arms in their final functional configuration, eliminating post-manufacturing adjustment and preserving geometric precision.
4Productivity
If a plurality of blanks are machined simultaneously, then production efficiency can be improved, but misalignment effects worsen because each blank's misalignment will be slightly different
Solution Approach 1:
Each blank in the batch is processed with the same two-step profile formation method, ensuring that local quality (geometric precision) is maintained uniformly across all blanks. The independent formation of first and second profiles in different orientation planes ensures that misalignment variations between blanks do not compound, maintaining alignment consistency throughout the batch.
Data Source
AI summary
The present disclosure is directed to medical devices and methods of manufacturing medical devices, such as an ophthalmologic medical device.