Automated Suturing Thread Tensioning for Prosthetic Implant Stitching
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Solution Overview
Problem
Manual suturing of prosthetic implants, particularly prosthetic heart valves, is challenging due to the need for high precision and efficiency, often resulting in labor-intensive and error-prone procedures.
Innovation Solution
An automated suturing system with coordinated fixtures and thread management, including a first automated fixture for positioning the implant and a second fixture for needle manipulation, along with an automated thread management system to provide targeted tension and clear the needle path, is employed to form precise stitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual suturing is performed by operators, then flexibility and adaptability are maintained, but labor intensity increases, error rate increases, and consistency decreases
Solution Approach 1:
The automated suturing system performs suturing operations autonomously without continuous human intervention. The robot executes pre-programmed suturing patterns, applies consistent tension, and completes high-precision suturing tasks independently, eliminating manual labor while maintaining high accuracy and consistency
Solution Approach 2:
Manual mechanical suturing operations are replaced with an automated robotic system that uses computer-controlled mechanisms for needle manipulation, thread tensioning, and suture formation. This substitution eliminates human error and labor intensity while maintaining operational flexibility through programmable control
2Manufacturing precision
If high precision suturing is performed manually, then accuracy can be achieved, but time consumption increases and efficiency decreases
Solution Approach 1:
The automated suturing system performs continuous suturing operations without interruption. The robot maintains constant needle movement, continuous thread feeding, and uninterrupted suture formation, eliminating the start-stop nature of manual suturing and significantly increasing throughput while maintaining precision
Solution Approach 2:
The system performs preliminary programming of suturing patterns, tension parameters, and movement trajectories before actual suturing begins. This pre-planning enables the robot to execute high-precision sutures at high speed without real-time decision-making delays, achieving both precision and efficiency simultaneously
3Ease of operation
If thread is managed during automated suturing, then needle path clearance is achieved, but system complexity increases
Solution Approach 1:
The automated suturing system integrates multiple functions into a single unified platform: needle manipulation, thread feeding, tension control, and path clearance all occur within the same robotic system. This multi-functionality reduces the need for separate dedicated devices while achieving effective thread management and needle path clearance
Solution Approach 2:
The system uses automated thread guides and tensioning devices as intermediaries to manage thread positioning and clearance. These intermediary components automatically redirect thread away from the needle path and maintain proper tension without requiring complex manual intervention or additional sophisticated mechanisms
Data Source
AI summary
The present disclosure relates to automated systems, devices, and methods of sewing a target device such as a prosthetic implant device. The systems and methods include forming a stitch on the target device, adjusting a thread coupled to a needle used to form the stitch so that the thread is clear of (e.g., does not interfere with) a path of the needle, and applying a targeted tension to the thread to tension the stitch on the target device. The suturing process can also include providing different targeted tensions during formation of the stitch. The suturing process can also include providing different targeted tensions at different stages of the formation of the stitch to aid in forming the stitch, to clear the needle path of the thread, and/or to hold the stitch in place in preparation for the next stitch.