Abstract: A process for manufacturing a surgical needle incorporates at least one pressing operation which, preferably, in conjunction with a trimming and/or etching process, ultimately forms the sharpened needle end. The grinding operation in the preferred process does not produce the primary sharpened edges of the needle, but, rather is incorporated, in one instance, to reduce excess needle material prior to the pressing operation. Consequently, the amount of flash material generated during pressing is substantially reduced. This feature desirably enhances the subsequent trimming and etching operations, and produces a needle which is extremely sharp, durable and exhibits an improved retention of sharpness over periods of prolonged use.

Abstract: Surgical needles are produced by immersing a needle possessing a distal end surrounded at least in part by flash material and a body portion in an acid bath according to a predetermined sequence, wherein the distal end of the needle is exposed to the acid bath under conditions sufficient to remove flash material from the distal end of the needle and the body portion of the needle is exposed to the acid bath under conditions sufficient to provide a matte finish on at least a portion of the body portion of the needle.

Abstract: A process for manufacturing a surgical needle incorporates at least one pressing operation which, preferably, in conjunction with a trimming and/or etching process, ultimately forms the sharpened needle end. The grinding operation in the preferred process does not produce the primary sharpened edges of the needle, but, rather is incorporated, in one instance, to reduce excess needle material prior to the pressing operation. Consequently, the amount of flash material generated during pressing is substantially reduced. This feature desirably enhances the subsequent trimming and etching operations, and produces a needle which is extremely sharp, durable and exhibits an improved retention of sharpness over periods of prolonged use.

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 method of removing edges from an eyeless operating needle blank includes the steps of providing needle blanks having an end portion which defines a bore. Aligning the end portion, which defines a bore, longitudinally with a laser. The laser is fired such that radiation from the laser is incident on the end portion. The incident radiation from the laser forms rounded edges about the end portion.

Abstract: A method for forming a surgical incision member of the type contemplated for use with a suturing apparatus incorporates the use of an energy beam system to form apparatus engaging notched portions in the incision member and a suture receiving aperture. A method is also disclosed for forming an elongated suture receiving bore in a conventional surgical needle utilizing an energy beam system.

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 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 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 apparatus for forming curved surgical needles is provided which includes a needle curving system for imparting an arcuate profile to sequentially presented needle blanks and a rotating system for pressing the needle blank against the curving system. The apparatus also includes needle supply and advancing systems for sequentially feeding and advancing the needle blanks to the needle curving system.

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 forming curved surgical needles is provided which includes a needle curving system for imparting an arcuate profile to sequentially presented needle blanks and a rotating system for pressing the needle blank against the curving system. The apparatus also includes needle supply and advancing systems for sequentially feeding and advancing the needle blanks to the needle curving system.

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.