Surgical Stapling Assembly with 3D-Printed Metal-Plastic Components
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Solution Overview
Problem
Current surgical stapling and cutting instruments face challenges in efficiently articulating end effectors to accurately position and maneuver during minimally invasive procedures, with existing articulation systems being complex and costly due to the need for multiple drive members and components that must fit through small trocar cannulas.
Innovation Solution
A surgical stapling system with a modular design featuring a dual-articulation joint mechanism that allows independent articulation of the end effector in two planes, using flexible drive members and 3D-printed components to enhance structural strength and flexibility, and incorporating a low durometer material for the anvil to accommodate tissue variations and reduce binding forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple drive members and components are used for articulation, then articulation precision is improved, but device complexity increases
Solution Approach 1:
The articulation system is divided into two independent single-degree-of-freedom articulation joints, each capable of articulating the end effector in a different plane. This segmentation allows precise control in multiple planes while keeping each joint relatively simple in structure
Solution Approach 2:
The dual-articulation joint mechanism serves multiple functions: it provides articulation in two planes, transmits drive motion efficiently, and accommodates the end effector at an angle relative to the longitudinal axis of the instrument shaft. This multi-functionality reduces the need for separate components for each function
2Productivity
If flexible drive members are used, then drive motion transmission efficiency is improved, but structural strength decreases
Solution Approach 1:
The drive shaft is constructed as a composite structure with a flexible outer covering and a rigid inner core. The flexible outer covering allows the drive shaft to bend and articulate, while the rigid inner core provides structural strength to transmit drive motion efficiently. This composite construction resolves the contradiction between flexibility and strength
3Manufacturing precision
If 3D-printed components are used, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The articulation joint is divided into multiple separately manufacturable components including a proximal articulation joint, a distal articulation joint, and an intermediate connection section. These segmented components can be manufactured using 3D printing technology with high precision, then assembled together, reducing overall manufacturing complexity and cost
Data Source
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AI summary
A surgical stapling assembly is disclosed. The surgical stapling assembly can include a first jaw, a second jaw, an articulation joint, a closure drive comprising a first flexible rotary drive extending through the articulation joint, and a firing drive comprising a second flexible rotary drive extending through the articulation joint and rotatable independent of the first flexible rotary drive. The surgical stapling assembly can further include a 3D-printed component. The 3D-printed component can include a plastic body and one or more metal substrates with interlocking features embedded in the plastic body. The surgical stapling assembly can include a firing member having a flexible portion configured to flex more readily that adjacent portions of the firing member.