Abstract: A device and method for cutting-to-length surgical suture material uses a thread spool having a continuous thread of the surgical suture material, a thread advancing gripper for drawing off a defined length of surgical suture material, and a cutting unit for cutting the surgical suture material. By way of a deflection installation, the surgical suture material is placeable so as to be angled to the primary transport direction in at least one open loop. The length of the open loop can be variably adjusted. The cutting unit is positioned between the thread spool and the deflection installation.

Abstract: A suture thread is used to perform suturing without tying part of or the whole of knots that are supposed to be tied during suturing. A suture thread support body prevents an end of the suture thread from being pulled into a suturing site. A needle accommodation body has a shape of a tube having a through-hole through both ends. The suture thread has the suture thread support body and the needle accommodation body.

Abstract: A method of attaching a surgical suture to a needle and testing the attachment includes dispensing a length of suture from a spool by using a first suture gripper, and using a surgical needle gripper for holding a surgical needle stationary. A leading end of the suture is inserted into and attached to a receiving end of the surgical needle. A second suture gripper is located between the first suture gripper and the spool. After the second suture gripper is closed for gripping the suture, the second suture gripper is advanced downstream toward the surgical needle to reduce the tension on the suture. The tension on the suture is reduced by moving the second suture gripper a pre-determined distance. The first suture gripper is opened for releasing the suture and the first suture gripper is moved toward the suture spool for re-grasping the suture at a location between the second gripper and the suture spool.

Abstract: A swaging system for attaching surgical needles to sutures and testing the attachment strength includes a frame, a bottom swaging die mounted on the frame, and a top swaging die mounted on the frame and being moveable up and down along a swaging axis that is aligned with the bottom swaging die. The bottom swaging die includes a hinge mechanism with a bottom plate mounted to the frame and a top plate overlying the bottom plate. The top and bottom plates are pivotally connected for enabling the top plate to pivot relative to the bottom plate. The bottom swaging die includes a swaging tool that extends toward the top swaging die along the swaging axis, and a load cell disposed between the top and bottom plates for monitoring load. The system includes a control system having one or more pull test programs stored therein for evaluating pull tests on armed surgical needles to determine if the armed surgical needles are acceptable or unacceptable.

Abstract: A collar arranged to couple to a prosthetic component for implantation at the end of a long bone, the prosthetic component having a distal portion arranged to couple to the bone and a proximal neck portion arranged to couple to an articulation component. The collar comprises a plate including a neck hole to receive a neck portion, such that the collar can rotate about the neck portion. The collar further comprises a plurality of attachment portions for coupling the plate to bone fragments or soft tissues. The collar is lockable to the neck portion to prevent further rotation. A prosthesis comprising a combination of a collar, a prosthetic component and an articulation component, and a surgical method of using the collar are also disclosed.

Abstract: In a process for producing a microneedle (12) that can be inserted into body tissue in which a needle tip (20) and a preferably capillary collecting channel (14) having a distal inlet for body fluid formed at the needle tip (20) are formed, it is provided that at least part of a preform (38) prefabricated from a flat material is shaped into a tubular structure (22) so that the collecting channel (14) is at least substantially annularly closed in the cross-section in the area of the tubular structure (22).

Abstract: Microneedle sheets are produced by injecting a needle raw material into a stamper formed with a concavity in a base material. However, because the stamper concavity is very small, there is the problem that air cannot escape due to air and surface tension of the material, thereby preventing a needle from being formed in part. The present invention provides a stamper for producing a microneedle sheet. The stamper comprises a sheet-like base material including a conical concavity formed from a first surface of the sheet-like base material toward a second surface thereof; and a through-hole formed from a bottom of the concavity toward the second surface. Air can escape via this through-hole, allowing a microneedle sheet which is filled with a needle raw material as far as the bottom of the concavity to be obtained.

Abstract: In a method of attaching a suture to a needle barrel, a first compression stroke compresses the radially-defined top of the barrel against a suture in the bore of the barrel while restraining the bottom and sides of the barrel against deformation. A second compression stroke compresses the bottom of the barrel against the suture while restraining the sides against deformation. In another method, the top and bottom are compressed concurrently while the sides are restrained against deformation. An apparatus for attaching a suture to a needle barrel includes two die sets, each including a die with a groove therein. In one die set, the groove protects the bottom and sides of the barrel from deformation while the top is compressed. In the other die set, the groove protects the sides of the barrel from deformation while the bottom is compressed.

Abstract: A method for manufacturing a surgical needle devoid of a grinding process includes the steps of swaging a needle blank to define a substantially tapered or conical needle end, pressing the tapered needle to form a plurality of intersecting surfaces and forming cutting edges along the lines of intersection of the intersecting sides. The needle may be subjected to an etching process (e.g., an acid bath) to sharpen the cutting edges and/or provide a matte finish on the needle. The needle produced by the novel process is extremely sharp and durable, and exhibits an enhanced retention of sharpness relative to conventional ground needles over periods of prolonged use.

Abstract: A quilting needle for achieving substantially uniform stitches in a multi-layer fabric/batten quilting substrate. The needle is formed as an elongated straight slender needle body having an eyelet at one end thereof sized for receiving a quilting thread therethrough and a sharp quilting fabric piercing point at another end of the needle body. A viewable stitch size guide is permanently disposed on the needle body so as not to disrupt the smooth needle body surface and is positioned from the point a distance equal to a desired stitch size. Successive stitches formed into the substrate of uniform size or length when the needle body is consistently pierced through the substrate to a depth defined when said stitch size guide just touches or meets and aligns with an obverse surface of the substrate before piercing the point into a reverse surface of the substrate to complete each stitch.

Abstract: A semi-automated machine and method for singulating individual surgical needles from an bulk supply and attaching a suture to the surgical needle is described. Each of the surgical needles has a suture receiving opening formed therein for receiving a suture. The machine includes a singulation station having a sliding surface that assists an operator in singulating needles and depositing them in a pair of drop locations for subsequent automatic handling. Indexing conveyors, an articulated robot and a precision conveyor are used with a precise positioning station for orienting each needle for automatic handling. A universal gripper mounted on a rotary indexing device automatically receives each individual needle in a predetermined orientation and conveys the needle for sequential processing from station to station to form the needle-suture assembly.

Abstract: A swaging apparatus for attaching sutures to surgical needles includes at least a first die and a second die. The first die has a first member, which includes a first surface, and a second member, which includes a second surface. The second member is movable relative to the first member between an extended position, in which the second surface extends beyond the first surface, and a retracted position, in which the second surface does not extend beyond the first surface. The second die has at least one surface and is movable relative to the first die between a remote position and an adjacent position. When the second die moves relative to the first die from the remote position towards the adjacent position, the second member of the first die is caused to move from the extended position towards the retracted position, and the surfaces of the first and second dies cooperate with one another so as to swage a surgical needle positioned between the first and second dies.

Abstract: A hypodermic needle featuring a multi-beveled point geometry is disclosed. In one embodiment, the multi-beveled point features a primary bevel, a pair of tip bevels, and a pair of middle bevels each intermediate the primary bevel and a respective one of the tip bevels. The primary and middle bevels are provided at angles of inclination, measured between the central axis and a reference plane that are substantially identical. The tip bevels are formed at an angle of inclination respective to the central axis which is not equal to the angle of inclination at which the primary and middle bevels are formed. The resulting five-beveled point geometry contributes to a more continuous bevel face free of abrupt intercepts or transitions between the respective bevel faces, lessening the penetration force required to urge the needle point through skin, flesh, or other material.

Abstract: A semi-automated machine for singulating individual surgical needles from an bulk supply and attaching a suture to the surgical needle is described. Each of the surgical needles has a suture receiving opening formed therein for receiving a suture. The machine includes a needle singulation station, a precise positioning station, a suture feeding station, a swage station, a pull-test station and an off-load station. The singulation station has a sliding surface that assists an operator in singulating needles and depositing them in a pair of drop locations for subsequent automatic handling. Indexing conveyors, an articulated robot and a precision conveyor are used with a pre-positioning and a precise positioning station for orienting each needle for automatic handling. A universal gripper mounted on a rotary indexing device automatically receives each individual needle in a predetermined orientation and conveys the needle for sequential processing from station to station to form the needle-suture assembly.

Abstract: There is disclosed an apparatus for forming curved and rectangular bodied needle blanks from a length of needle stock which includes a generally cylindrical inner mandrel having a plurality of longitudinal channels formed in an outer surface thereof, the mandrel being dimensioned and configured for insertion within the length of needle stock. The apparatus also includes a plurality of broaches insertable into the longitudinal channels such that an edge of each broach projects radially outwardly of the mandrel to form a plurality of inner grooves on an inner surface of the length of needle stock.

Abstract: A process for progressively manufacturing cutting edge needles or wire members. Needle blanks or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of coining dies and at least one trimming die, wherein the first coining die is an open coining die and the one or more successive coining dies are closed coining dies. The needle blanks or wire members are optionally curved, heat treated and electrochemically treated resulting in cutting edge needles or wire members formed without a grinding step and without adversely affecting point ductility.

Abstract: There is disclosed an apparatus and method for forming curved and pointed needle blanks from a coiled length of wire needle stock material. The apparatus includes an inner mandrel having a circumferential wire receiving groove and at least one longitudinally extending broach receiving channel formed in the outer surface. The apparatus also includes an outer member having an inner surface defining a bore sized to receive the inner mandrel wrapped with wire needle stock. The outer member includes at least one longitudinal broach receiving channel formed in the outer member inner surface. The outer mandrel further includes a circumferential wire receiving groove formed in the inner surface such that, when wrapped with the length of wire needle stock material, the inner mandrel is threaded into the outer member. The apparatus further includes at least one broach which is movable within the channels to cut the length of wire needle stock into curved and pointed needle blanks.

Abstract: There is disclosed an apparatus and a method for progressively forming high strength surgical needles from bulk needle stock material. The apparatus generally includes a series of progressive needle processing stations. A first series of needle processing stations removes material from needle stock material to rough form needle blanks attached to a carrier strip while a second series of processing stations refine the rough formed needle blanks attached to the strip into the desired surgical needles. The disclosed method generally includes the steps of gutting needle stock material to rough form needle blanks attached to a carrier strip and progressively coining the rough formed blanks into surgical needles. Finally, there is disclosed a high bend strength surgical needle formed on the disclosed apparatus or by the disclosed method. Preferably, the surgical needle is a surgical incision member having a predetermined radius of curvature and an optimized conical radius at the tips.

Abstract: A method and apparatus for attaching sutures to curved surgical needles. A vibratory bowl and vibratory rail function to present individual surgical needles to a transfer system in a predetermined orientation. The transfer system then delivers each oriented needle to a frame which positions the needle for subsequent swaging by a rotating die system which selectively impacts the needle to secure the suture thereto.

Abstract: An apparatus is disclosed for attaching a surgical needle having a generally cylindrical end portion defining an elongated aperture having a generally circular cross-section and a suture having a generally elongated end portion of generally circular cross-section corresponding in dimension to the elongated aperture of the needle. The apparatus includes a pair of dies, each having a die face with an inner die surface portion. The inner die surface portion includes at least one generally planar crimping surface having an arcuate recess formed therein which extends along at least a portion of the planar crimping surface.

Abstract: There is disclosed an apparatus for forming a surgical incision member comprising which includes a first die associated with a base and having a first groove therein for receipt of at least a portion of a needle blank. A second die is mounted for movement on the base between a position remote from the first die and a position adjacent the first die. The second die includes a second groove alignable with the first groove to hold a needle blank therebetween, the first and second dies each having spaced apart channels intersecting the first and second grooves. A notching die is provided and is mounted for movement within at the channels so as to engage and notch an edge of the needle blank contained within the first and second grooves. The apparatus also includes structure for curving a needle blank contained within the first and second grooves. A method of forming a surgical incision member is also disclosed, and a surgical incision member blank.

Abstract: An apparatus for forming at least one curved, rectangular bodied surgical needle which comprises frame means, flat press means associated with said frame means for imparting first flat surfaces to opposite sides of at least a portion of at least one needle blank, curving means associated with said frame means for imparting an arcuate profile to at least a portion of the at least one needle blank and side press means mounted on said frame portion for imparting second flat surfaces to opposite sides of the needle blank, wherein said second flat surfaces are imparted substantially perpendicular to said first flat surfaces.

Abstract: An apparatus for preparing drilled needle blanks from a spool of coiled stock wire may include a laser for drilling a bore in the end of the stock wire and a cutting device for cutting the drilled wire into needle blanks.

Abstract: An apparatus having a frame; a shuttle member, adapted to receive and hold a needle blank, and movably mounted to the frame; a clamp member detachably mounted on the frame for supplying needle blanks to the shuttle member; a transfer mechanism mounted on the frame for facilitating the transfer of the needle blanks from the clamp member to the shuttle member; a press mechanism for imparting first flat surfaces to first opposing sides of the needle blanks held by the shuttle member; a mandrel mounted on the frame for imparting an arcuate profile to the needle blanks; a transport mechanism for transporting the needle blanks from the shuttle member to the mandrel; and a needle side press for imparting second flat surfaces to second opposing sides of the needle blanks.

Abstract: An automated machine for attaching a suture to a surgical needle comprises a first apparatus located at a first predetermined location for sorting a plurality of randomly oriented needles and orienting each needle for automatic handling at a first predetermined location, each of the needles having a suture receiving opening formed therein. A second apparatus located at a second predetermined location is provided for automatically cutting an indefinite length of suture material to a definite length suture strand and for automatically inserting an end of the definite length suture strand into the suture receiving opening formed in the needle. Also provided is a third apparatus for swaging the needle to close the suture receiving opening about the suture to secure said suture thereto and form therefrom a needle and suture assembly.

Abstract: An apparatus for curving a needle is provided which comprises at least two generally cylindrical members rotatably connected to a frame. At least one anvil shaft is positioned substantially between the cylindrical members and is rotatably connected to the frame. A needle is positionable between the anvil shaft and the cylindrical members such that the needle is curvable about the anvil shaft. A driving assembly rotates the cylindrical members and the anvil shaft such that the needle is curved about the anvil shaft and expelled from the apparatus.

Abstract: The present invention relates to a needle curving apparatus for curving one needle or a multiplicity of needles simultaneously. The apparatus includes a curving system for bending the needle and a reciprocating drive system for biasing the needle blanks against the curving system and reciprocally moving the needle blanks to form the curved needle.

Abstract: The present invention relates to an apparatus and method for positioning and pressing surgical needle blanks. The apparatus includes a needle blank transferring system which transfers needle blanks between a gripping position and a pressing position. A side press system presses a portion of the needle blank when the blank is in the pressing position, and a gripping member is provided to hold the needle blank at least during the transfer and press operations of the apparatus. The method according to the present invention includes inserting a needle blank into a needle blank gripping member at a gripping position, transferring the needle blank between the gripping position and a pressing position, and pressing a side portion of a body portion of the needle blank with pressing dies.

Abstract: An apparatus for preparing drilled needle blanks from a spool of coiled stock wire may include a laser for drilling a bore in the end of the stock wire and a cutting device for cutting the drilled wire into needle blanks.

Abstract: A crimping apparatus for crimping a root end of an eyeless needle to fix a medical suture between an upper mold and lower mold. This apparatus comprises a swing arm disposed in parallel with the root end of the eyeless needle and the upper mold fixed to the swing arm. This apparatus also comprises a pivoting axis of the swing arm, being long enough to a crimping length of the eyeless needle. This pivoting axis is disposed far enough from the upper mold.

Abstract: An apparatus for forming a curved, flat sided surgical needle, which comprises a frame member including an anvil member having an arcuate surface profile; a movable first die member for simultaneously imparting an arcuate profile and at least a pair of first opposing flat surfaces to a body portion of a needle blank and adapted to receive a needle blank, the first die member having an arcuate needle forming surface which is substantially parallel to the arcuate surface of the anvil member; a first side tool for curving a tapered end portion of the needle blank about the anvil; a transfer tool adapted to slide the needle blank along the anvil a side press adapted to import second flat surfaces to a second pair of opposing sides of the body portion of the needle blank; a second side tool member for curving a drill end portion of the needle blank about the anvil; and an ejection tool for moving the needle blank away from the anvil.

Abstract: An apparatus for presenting a curved workpiece to a workstation, includes a frame member and a guide channel associated with the frame member for receiving a curved workpiece in a generally upright position. A first pusher mechanism is reciprocally movable in a transverse direction relative to the guide channel for engaging and positioning the workpiece against a bearing surface of the guide channel. A second pusher mechanism is advanceable within the guide channel to engage the workpiece and to advance the workpiece to the workstation. The apparatus has particular application in the manufacture of curved surgical needles.

Abstract: Apparatus for forming curved needles from needle blanks of differing sizes and material characteristics having a guide die, driven by a linear actuator, for biasing the needle blank against a forming surface. Bending dies also driven by linear actuators are provided for bending the ends of the needle blank around the top of the forming surface. Adjusting micrometers are provided to adjust the contact point at which the bending dies contact the needle blank. The apparatus can therefore be readily adapted for differing needle stocks. The entire bending process is automated so that uniform needles may be rapidly produced.

Abstract: A single-strike die mechanism includes a rotatable cam drive ring driven to impart through a cam mechanism linear motion to at least three crimping dies. The crimping dies are symmetrically arranged within a die guide and simultaneously actuated to move in a radial direction toward a centerline of a surgical needle. A surgical suture is axially inserted within a hollow barrel end of the needle, and the barrel end is crimped by the crimping dies to secure the suture therein. A method for operating the single-strike die mechanizes the procedure for securing the suture within the barrel end of the needle.

Abstract: An improved surgical needle is disclosed. The needle has a butt. The butt has a proximal and a distal end. A blind hole is in the butt. The hole originates at the proximal and terminates at the distal end of the butt. A crimp is adjacent to the butt. The improvement to the crimp comprises a first and a second side that are essentially parallel. A third side is essentially perpendicular to the first and second sides. A fourth side is curvilinear. The curvilinear fourth side can be a semicircle. A machine and a method of attaching a surgical suture to the improved needle is also disclosed.

Abstract: An improved surgical needle is disclosed. The needle has a butt. The butt has a proximal and a distal end. A blind hole is in the butt. The hole originates at the proximal and terminates at the distal end of the butt. A crimp is adjacent to the butt. The improvement to the crimp comprises a first and a second side that are essentially parallel. A third side is essentially perpendicular to the first and second sides. A fourth side is curvilinear. The curvilinear fourth side can be a semicircle. A machine and a method of attaching a surgical suture to the improved needle is also disclosed.

Abstract: An improved surgical needle is disclosed. The needle has a butt. The butt has a proximal and a distal end. A blind hole is in the butt. The hole originates at the proximal and terminates at the distal end of the butt. A crimp is adjacent to the butt. The improvement to the crimp comprises a first and a second side that are essentially parallel. A third side is essentially perpendicular to the first and second sides. A fourth side is curvilinear. The curvilinear fourth side can be a semicircle. A machine and a method of attaching a surgical suture to the improved needle is also disclosed.

Abstract: An apparatus for connecting a thread wound on a bobbin to a surgical needle including feeding rollers for unwinding the thread from the bobbin, a tube-like chuck for selectively fix the thread thereto, a guide for guiding the front end of the thread, a feeding device for supporting the needle such that a hole formed in a rear end face of the needle is faced to the front end of the thread, and a clamping device having pushing rods for pressing the rear end of the needle to clamp the thread in the hole. By moving the needle to the guide, the front end of the thread is inserted into the hole of the needle, and then the clamping device is driven to press the rear end of the needle so that the thread is clamped in the hole. Then, the thread is unwound from the bobbin by a desired length by moving the feeding device away from the guide, and finally the thread is cut along an inclined line.

Abstract: A large number of needle patterns are integrally associated with each other on an extended U-shaped metal plate. After that, a pointed end of individual needle patterns is formed, and a series of individual needle patterns are divided into a plurality of segmented needle bodies. Then, a suture is inserted into a hollow portion of the needle body. By closing both walls of the needle body, a suture needle can be produced one after another.

Abstract: An apparatus for attaching an end of a suture to an axially extending bore formed in a proximal end of a surgical needle. At least one of a pair of staking dies is movable toward and away from the other. A proximal end face of the surgical needle is engageable with a stopper surface of a guide unit to axially position the surgical needle. The guide unit has a guide passage extending substantially perpendicularly to the stopper surface, for guiding the end of the suture. An outlet of the guide passage opens to the stopper surface in confronting relation to a space between the staking dies. The guide passage has a tapered portion decreasing in cross-sectional area toward the outlet. The proximal end of the surgical needle is positioned by a positioning mechanism perpendicularly to the axis of the surgical needle so that the bore in the surgical needle is brought substantially into alignment with the outlet of the guide passage.

Abstract: A method of and an apparatus for staking a proximal end of an operating needle, with one end of a suture being inserted into a bore in the proximal end of the needle, to attach the suture to the needle. A staking unit has a pair of staking disc at least one of which is movable relative to the other. The dies are respecitvely provided therein with recesses between which the proximal end of the needle is staked. The staking unit is mounted on a table so as to be demountable therefrom. An electric power supply unit is provided which is separate from the staking unit, but is connected thereto through a plug and a socket. A foot switch is connected to the power supply unit for controlling the operation of the staking unit. A plurality of the staking units are prepared which include their respective pairs of staking dies different in dimension of the recesses from each other. One of the staking units is selected, which includes its corresponding pair of staking dies adapted to a needle to be staked.

Abstract: A large number of needle patterns are integrally associated with each other on an extended U-shaped metal plate. After that, a pointed end of individual needle patterns is formed, and a series of individual needle patterns are divided into a plurality of segmented needle bodies. Then, a suture is inserted into a hollow portion of the needle body. By closing both walls of the needle body, a suture needle can be produced one after another.

Abstract: A device for transporting bar-shaped workpieces, particularly blanks for sewing machine needles, between the stop positions of a follow-on tool, includes one or more transport spindles extending over the length of the follow-on tool and having a threaded section arranged for form-locked engagement with the workpiece, the threaded section being interrupted by a lead-less section in the region of a predetermined stop position, the lead-less section extending over an angle corresponding to a predetermined stop time.

Abstract: Needle-suture combinations are provided wherein a needle having an axial opening in the blunt end thereof for receiving a suture is bonded to the suture with a hot melt wax composition having sufficient bonding strength to secure the needle to the suture during surgical procedures, but which allows the needle to be deliberately removed from the suture by a sharp tug at the completion of the surgical procedure. Needle pulloff values in the range of 1 to 56 ounces (0.028 to 1.58 kg) are readily obtained.

Abstract: A controlled release needle-suture combination wherein a fluid swellable suture is attached to a surgical needle having an oversized blind axial opening by inserting the suture into the full depth of the opening and swaging the needle over the outermost portion of the opening so that the end of the suture at the innermost portion of the opening remains uncompressed. Such needle-suture combinations are characterized by having relatively uniform and consistent needle pull-off values regardless of changes in the fluid content of the suture.

Abstract: Surgical needles are attached to sutures with controlled pull-out characteristics by a short crimp--that is a crimp whose length is markedly less than the length of the end of the suture in the needle; with an essentially undistorted portion of the needle adjacent to where the suture emerges from the needle, and an essentially undistorted portion around the front of the suture, so that only a short section of the needle is crimped around the suture. This leaves the suture uncrushed where it emerges from the needle and hence of superior strength where sharp bends occur during use. It also leaves an undistorted portion of the suture ahead of the crimp so that on pull-out, the suture is retained not only by frictional engagement of the crimp but also by the forces required for the distortion of the head of the suture so that it will pull through the reduced section of the crimp.

Abstract: A method is provided for anchoring a suture to a needle in which a suture tip is inserted into a recess in the blunt end of a needle and the needle is thereafter heated to expand the suture tip within the recess into tight engagement with the recess walls. Sutures of synthetic polymers attached in this manner are removable from the needle by application of a straight pulling force of less than about 30 ounces.

Abstract: A needle-suture combination is provided in which a lubricant layer is provided at the juncture between the needle and the suture and specifically between the inner surfaces of a recess in the blunt end of the needle and the outer surface of one tip of the suture which is inserted into the recess and in tight engagement with at least a portion of the inner surface of the recess. The lubricant lowers the pull-out value of the needle-suture combination.

Abstract: A needle-suture combination is provided in which the suture has a weakened segment adjacent its attachment to the needle. The weakened segment is provided by a notch which reduces the effective cross-sectional area of the suture by a controlled amount. The weakened segment permits a surgeon to separate the needle from the suture by a sharp tug.