Customizing Surgical Dissectors Using 3D Printing

This patent describes a surgical tool's working tip, called an end effector, which has two jaws whose gripping features can be custom-made using 3D printing for specific surgical needs.

What it covers

The patent describes a surgical end effector, which is the working tip of a surgical instrument, featuring two jaw members that can open and close. The key innovation is that at least one specific 'feature' on these jaws can be chosen by a user and created using an 'additive manufacturing process' (Claim 1). This means a surgeon or manufacturer can design unique patterns or shapes on the gripping surfaces of the jaws, such as a 'tooth' on one jaw and a complementary 'void' on the other (Claim 4), or even use different materials for different features (Claims 5, 6). For example, a surgeon could specify a unique symmetrical pattern of protrusions on one jaw and a complementary pattern on the other for a specialized tissue grip (Claim 7), then have it 3D printed.

What it doesn't cover

• —Surgical instruments that do not include two jaw members that are independently movable relative to each other (Claim 1).
• —End effectors where neither the first feature of the first jaw member nor the first feature of the second jaw member is selected by a user in an additive manufacturing process (Claim 1).
• —Manufacturing methods for the jaw features that are not additive manufacturing, such as traditional molding or machining (Claim 1).
• —Surgical tools where the jaw members do not pivot about a joint between an open and closed configuration (Claim 1).
• —Dissectors where the features on the jaws are fixed and cannot be customized or varied by a user during manufacturing.

The clever bit

The novelty lies in integrating user-selected, additive manufacturing (like 3D printing) directly into the design and production of specific functional features on surgical jaw members. This allows for on-demand, customized surgical implements rather than relying solely on mass-produced, generic tool designs.

Why it matters

This patent is significant because it enables the creation of highly specialized surgical tools. By using additive manufacturing, instruments can be tailored precisely for unique patient anatomies or specific surgical tasks, potentially improving precision and outcomes. The assignee, Ethicon LLC, is a major medical device company, indicating a strategic focus on advanced manufacturing for personalized surgical solutions.

Real-world examples

• 1.Custom surgical dissectors for specific tissue types
• 2.Specialized grasping tools for delicate or unusually shaped organs
• 3.Instruments for minimally invasive surgery requiring unique geometries
• 4.3D-printed medical devices with tailored gripping surfaces