Surgical Stapler Cartridge 3D Printed Alignment Features
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Solution Overview
Problem
The manufacturing process of surgical stapling assemblies is complex, costly, and time-consuming due to the precise fit and alignment requirements of staple drivers and cartridge bodies, which can lead to issues like breakage or incomplete stapling.
Innovation Solution
The use of 3D printing to integrate alignment features with staple drivers and cartridge bodies, ensuring a precise fit and reducing the complexity of the manufacturing process, while allowing for rapid production and prototyping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for surgical stapling assemblies, then manufacturing precision can be maintained, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The patent integrates the alignment feature directly into the staple driver component, merging two previously separate functions (staple driving and alignment) into a single integrated component. This reduces the number of parts and simplifies the manufacturing process while maintaining precise alignment through the integrated feature geometry.
Solution Approach 2:
The staple driver is designed to perform multiple functions: it drives the staple through tissue and simultaneously provides alignment guidance through its integrated alignment feature. This multi-functional design eliminates the need for separate alignment mechanisms, reducing manufacturing complexity while maintaining precision.
2Manufacturing precision
If traditional manufacturing processes are used for surgical stapling assemblies, then component fit can be controlled, but production time and cost increase
Solution Approach 1:
The alignment feature is pre-integrated into the staple driver design, establishing the precise fit relationship between components during the manufacturing process itself rather than requiring post-assembly adjustments. This preliminary integration of alignment functionality accelerates production while ensuring consistent component fit.
Solution Approach 2:
The patent modifies the geometric parameters of the staple driver by incorporating the alignment feature directly into its structure. This parameter change in the component design enables both precise fit control and faster production by eliminating separate alignment components and assembly steps.
3Manufacturing precision
If separate alignment features are used, then alignment precision can be achieved, but the number of components and manufacturing steps increase
Solution Approach 1:
The alignment feature is merged with the staple driver body, creating a single integrated component rather than using separate alignment elements. This merging maintains alignment accuracy through the integrated feature geometry while reducing the total component count and simplifying the assembly process.
Data Source
AI summary
An apparatus includes a staple, a body, a staple driver, and an alignment feature. The alignment feature is coupled to or formed with at least one of the staple driver or an inner surface of the staple aperture of the body. The alignment feature is configured to minimize rotation of the staple driver. The alignment feature includes at least one of a first contact feature, an alignment member, an alignment member, or an inwardly tapering portion. The first contact feature projects beyond a first lateral side of the staple driver. The alignment member extends through at least a portion of the staple driver. The first connecting portion rigidly connects the inner surface of the staple aperture with the staple driver in a connected state. The inwardly tapering portion of the inner surface or the staple driver is configured to guide the staple driver.