Abstract: A process of forming a one piece weld free endoscopic shaver blade from an elongate metal cylindrical tube includes first cutting the tube first distal end to a predefined opening shape. A mandrel is inserted into the longitudinal tube with its working end adjacent the tube distal end. The tube distal end is further supported and a first die is forced thereon in a direction generally perpendicular to the elongate tube and forming the tube end and defining a shaver blade opening. A second die is forced onto the tube first distal end in a direction generally parallel to the tube longitudinal further forming the tube end and shaver blade opening. The formed shaver blade opening is then machined or edgeformed as needed to a final shaver blade opening and perimeter shape.

Abstract: A current pickup assembly for placing electrical current on a moving wire electrode in an electrical discharge machine apparatus and having a normal straight line of travel. The current pickup assembly includes a current pickup having a bore therethrough for receiving the wire electrode. The bore longitudinal axis is at an angle with respect to the normal straight line of wire travel and the moving wire electrode contacts the bore contact wall therein. A pivot means is provided for selectively pivoting the carbide pickup longitudinal axis at an angle with respect to the straight line of wire travel. A rotation means rotates the current pickup about the bore longitudinal axis. In the alternative, the current pickup is supported on a gimball means for selectively pivoting the pickup about two mutually perpendicular and intersecting axes of rotation intersecting at a point.

Abstract: A guide assembly for guiding an electrical discharge machine apparatus moving wire electrode through a workpiece. The guide assembly includes first, second, and third guide members, each having a bore for receiving the moving wire electrode and a current pickup is located between the second and third guide members. The first guide member is closest to the workpiece. The first and second guide members are mounted on a guide body at respective first and second openings communicating with one another through a wire passageway through the guide body. The guide body includes a threaded portion and a nut member is used for engaging the threaded portion and attaching the guide body to the support assembly. The nut member includes a housing defining a fluid passageway and an outlet bore for creating a threading fluid stream.