Surgical Stapler Lower Jaw Stamping for Precision With Less Machining
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Solution Overview
Problem
Conventional manufacturing processes for surgical stapling instruments are time-consuming, expensive, and inefficient, particularly in machining lower jaws, which can lead to material waste and undesirable stress, and often require tight tolerances for optimal performance.
Innovation Solution
A method of manufacturing lower jaws using a combination of near net shape forming processes such as stamping and subsequent machining, allowing for efficient, cost-effective production with improved dimensional accuracy and reduced material waste, while maintaining the necessary tolerances for surgical instrument functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining processes are used to manufacture lower jaws, then manufacturing precision can be achieved, but production time increases and material waste occurs
Solution Approach 1:
The lower jaw is pre-formed using near-net-shape forming processes (such as investment casting or machining from blank) to establish the basic geometry and approximate dimensions before final precision machining. This preliminary formation removes the bulk of material and creates the rough shape, so that subsequent precision machining only needs to remove minimal material to achieve final tolerances, thereby significantly reducing total production time while maintaining dimensional accuracy
Solution Approach 2:
The manufacturing process is divided into distinct stages: (1) near-net-shape forming to create the basic lower jaw geometry, (2) selective precision machining of only those surfaces requiring tight tolerances (such as the staple receiving surface and anvil interface), and (3) final assembly. This segmentation allows each stage to be optimized independently, reducing overall production time while maintaining necessary precision
2Manufacturing precision
If conventional machining processes are used to manufacture lower jaws, then manufacturing precision can be achieved, but material waste increases
Solution Approach 1:
The lower jaw is pre-formed using near-net-shape forming processes (such as investment casting or machining from blank) to establish the basic geometry and approximate dimensions before final precision machining. This preliminary formation removes the bulk of material and creates the rough shape, so that subsequent precision machining only needs to remove minimal material to achieve final tolerances, thereby significantly reducing total production time while maintaining dimensional accuracy
Solution Approach 2:
The manufacturing approach transitions from traditional subtractive machining (which removes large amounts of material) to near-net-shape forming processes that build the part close to its final shape. This parameter change in the manufacturing method fundamentally reduces material waste while still achieving the necessary dimensional accuracy through selective finishing operations
3Manufacturing precision
If conventional machining processes are used to manufacture lower jaws, then manufacturing precision can be achieved, but production cost increases
Solution Approach 1:
The lower jaw is pre-formed using near-net-shape forming processes (such as investment casting or machining from blank) to establish the basic geometry and approximate dimensions before final precision machining. This preliminary formation removes the bulk of material and creates the rough shape, so that subsequent precision machining only needs to remove minimal material to achieve final tolerances, thereby significantly reducing total production time while maintaining dimensional accuracy
Solution Approach 2:
The manufacturing process is divided into distinct stages: (1) near-net-shape forming to create the basic lower jaw geometry, (2) selective precision machining of only those surfaces requiring tight tolerances (such as the staple receiving surface and anvil interface), and (3) final assembly. This segmentation allows each stage to be optimized independently, reducing overall production time while maintaining necessary precision
4Manufacturing precision
If conventional machining processes are used to manufacture lower jaws, then manufacturing precision can be achieved, but stress in the component increases
Solution Approach 1:
The manufacturing approach transitions from traditional subtractive machining (which removes large amounts of material) to near-net-shape forming processes that build the part close to its final shape. This parameter change in the manufacturing method fundamentally reduces material waste while still achieving the necessary dimensional accuracy through selective finishing operations
Data Source
AI summary
A method is used to manufacture a lower jaw of an end effector of a surgical instrument. The method includes providing a lower jaw that includes a U-shaped body portion. The U-shaped body portion includes a bottom wall interposed between first and second opposing side walls. The method also includes forming at least one feature into at least one of the first and second side walls, wherein the at least one feature has a near net shape. The method also includes subsequently machining the at least one feature to have a machined shape.