Surgical Jaw Gap Manufacturing via Metal Injection Molding
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Solution Overview
Problem
Designing endoscopic electrosurgical forceps for small cannula openings poses manufacturing challenges due to the complexity of instruments like electrosurgical forceps, which require precise jaw configurations and reduced component complexity to maintain tissue seal integrity through smaller diameters.
Innovation Solution
The development of an endoscopic bipolar forceps assembly with a simplified design featuring a shaft with movable jaw members and a reciprocating blade, where the blade contacts the undersurface of an opposite jaw member to define a gap for effective tissue sealing, and the use of materials like ceramic and metal injection molding for precise tolerances and mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining and assembly methods are used for electrosurgical forceps, then manufacturing precision can be maintained, but device complexity and difficulty of manufacture increase significantly when reducing instrument size for small cannula openings
Solution Approach 1:
The jaw member integrates multiple functions into a single component: the jaw body, sealing surface, and gap-defining features are combined into one monolithic structure formed by metal injection molding. This eliminates the need for separate stop members, gap-defining components, and multiple assembly steps, thereby reducing device complexity while maintaining manufacturing precision for small cannula-compatible instruments
Solution Approach 2:
The jaw member serves multiple purposes simultaneously: it provides tissue grasping surfaces, defines the sealing gap through integrated geometric features, supports the sealing surface, and enables cutting blade reciprocation. This multi-functionality reduces the total component count and assembly complexity while maintaining the precision required for effective tissue sealing through smaller cannula openings
2Length of moving object
If instrument size is reduced to fit through smaller cannula openings, then surgical benefits are improved, but manufacturing precision and component integrity become increasingly difficult to maintain
Solution Approach 1:
The invention transitions from conventional machining methods to metal injection molding, changing the manufacturing process parameters and capabilities. This enables production of complex three-dimensional jaw geometries with integrated gap-defining features at smaller scales, achieving the necessary manufacturing precision for jaw gap tolerance and component integrity in instruments designed to fit through five millimeter or smaller cannula openings
Solution Approach 2:
Metal injection molding utilizes composite material technology, combining metal powders with organic binders to create feedstock that can be injected into molds. This process enables precise formation of complex jaw geometries with tight tolerances at small scales, maintaining component integrity and manufacturing precision while reducing instrument diameter to fit through smaller cannula openings
3Adaptability or versatility
If multiple separate components are used for jaw members and gap control, then adjustability is improved, but ease of manufacture decreases for small diameter instruments
Solution Approach 1:
The jaw member is designed as a single integrated component formed by metal injection molding, combining the jaw body, sealing surface, and gap-defining geometric features into one manufacturable unit. This eliminates the need for separate stop members, gap-adjustment mechanisms, and complex assembly procedures, significantly improving ease of manufacture for small diameter instruments while maintaining functional versatility through integrated design features
Data Source
AI summary
An endoscopic forceps includes an elongate shaft defining an instrument axis. An end effector includes first and second jaw members each supporting an opposed sealing surface for clamping tissue. At least one of the jaw members is movable relative to the instrument axis such that the jaw members are movable between a first spaced-apart configuration and a second closed configuration for grasping tissue. A cutting instrument includes a reciprocating blade translatable relative to the sealing surfaces to sever tissue clamped between the jaw members. The reciprocating blade contacts an undersurface of at least one of the jaw members when the jaw members are in the second configuration to define a gap distance between the sealing surfaces. A handle adjacent the proximal end of the elongate shaft is operable to induce motion in the jaw members, and an actuator is operable to selectively translate the reciprocating blade.