Abstract: An active anvil assembly for use in forming a looped suture is provided. The active anvil assembly includes an anvil member, a first sensor operably connected to the anvil member, and a control assembly. The first sensor is configured for measuring at least one of force, torque, and distance feedback. Also provided are systems and methods for forming a looped suture including an active anvil assembly.

Abstract: A mounting assembly for use in forming a looped suture is provided. The anvil assembly includes a first anvil configured to operate with a welding assembly to join a first length of a thread and a second length of the thread to form a loop in the thread. The first anvil is selectively movable in at least first and second directions relative to a welding assembly. The anvil assembly may further include a second anvil configured to operate with a trimming assembly to remove excess thread from the loop, wherein the second anvil is selectively movable in at least first and second directions relative to the trimming assembly.

Abstract: A station for cutting a barb suture is provided. The barb cutting station includes a suture transport assembly for supporting a first suture, a first knife assembly for forming barbs on the first suture, and a first clamp and position assembly for approximating the at least first suture towards the at least first knife assembly. The barb cutting station may further include at least a first suture cutting mechanism configured for severing the at least first suture when a defect is detected. The station may also include at least a first visual inspection assembly configured for detecting defective barbs.

Abstract: A system for forming a looped suture is provided. The system includes a suture supply assembly configured for supplying thread, a flipper gripping assembly configured for forming a loop in the thread, a carriage assembly configured for advancing the thread through the forming process, and a welding assembly configured for securing the loop in the thread.