Stamped Curved Surgical Stapler Frame With Segmented Assembly
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Solution Overview
Problem
Conventional manufacturing processes for surgical stapler frames are time-consuming, expensive, and inefficient, often requiring machining from a single solid block of material, which results in waste and high costs.
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 by forming components separately and coupling them together using fasteners or welding, reducing material waste and improving tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining from a single solid block is used, then manufacturing precision and structural integrity are improved, 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 using fasteners. This segmentation allows each component to be produced efficiently through high-speed stamping while maintaining the overall structural integrity of the frame assembly.
2Strength
If conventional machining from a single solid block is used, then structural integrity is improved, but material waste and manufacturing cost increase
Solution Approach 1:
The frame is segmented into multiple components that are manufactured separately through stamping processes, which are near-net-shape processes with minimal material waste. The components are then joined using fasteners to create the complete frame assembly, achieving both material efficiency and structural integrity.
Solution Approach 2:
The frame assembly functions as a composite structure combining multiple metal components joined through fasteners. This composite approach allows each component to be optimized for its specific function while maintaining overall structural strength, and enables the use of stamping processes that minimize material waste.
3Ease of manufacture
If conventional machining from a single solid block is used, then manufacturing simplicity is improved, but production cost and time increase
Solution Approach 1:
The frame is divided into multiple components manufactured separately through stamping processes, which are highly efficient for mass production. The segmented components are then assembled using standard fasteners, allowing for parallel manufacturing and reduced overall production time while maintaining manufacturing simplicity through standardized processes.
4Productivity
If alternative manufacturing methods like stamping are used, then production efficiency and cost-effectiveness are improved, but manufacturing complexity increases
Solution Approach 1:
The frame is segmented into multiple components that can be manufactured using efficient stamping processes. The segmentation enables parallel production of components and simplifies the manufacturing workflow, while the use of standard fasteners for assembly reduces the complexity of joining operations.
Solution Approach 2:
The frame design incorporates universal features such as standard fasteners and modular components that can be manufactured using common stamping processes. This universality allows the same manufacturing techniques and assembly methods to be applied across different frame configurations, reducing overall manufacturing process complexity.
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.