Abstract: An apparatus and method for thermally forming a surgical suture tip from a length of unfinished surgical suture material having a varying cross-section. The thermally formed surgical suture tip has a generally uniform cross-section along its length, and the varying cross-section corresponds to a distribution of different cross-sectional sizes along the length of the unfinished surgical suture material. A first heating die has a first face with a first groove therein for receiving a portion of the length of the unfinished surgical suture material, and a second heating die has a second face with a second groove therein. The first and second grooves extend along a common axis. At least one mechanical actuator is provided for moving the first face of the first heating die against the second face of the second heating die and for contacting the first and second grooves against an outer surface of the unfinished surgical suture material.

Abstract: A surgical suture comprised of a first thermally formed tip portion having a first length which is adjacent to a body portion having a second length. The first thermally formed tip portion has a generally uniform cross-section perpendicular to the first length, while the body portion has a varying cross-section which corresponds to a distribution of different cross-sectional sizes along the second length. The generally uniform cross-section of the first thermally formed tip portion has an average cross-sectional size that is less than the average of the different cross-sectional sizes along the second length.