Computerized system and method of manufacturing an articulated surgical device. Surgical device pathway data (often from medical scans), target and entry point location data, and design parameters in computer memory are used to automatically design, and subsequently manufacture the customized device. The device typically comprises a plurality of units, which may have varying lengths and widths, connected to other units by at least one moveable joint. The device is configured to accommodate multiple pull cables, often running from the distal to the proximal end. These cables enable an operator, often using a proximal control device, to precisely control the orientation of the distal end as the device traverses a patient's body pathways. The distal end of the device may have an effector unit configured to perform a medical task. Design and manufacture are facilitated by use of AI computerized design methods and computer controlled (CNC, laser cutting, 3D printing) methods.

A steerable catheter system may include a flexible elongate catheter body, a drive mechanism at the proximal end of the catheter body, and at least one group of pullwires extending along a length of the catheter body. The catheter body may include a distal articulating section and a proximal non-articulating section. Each group of pullwires includes at least two pullwires, and each of the pullwires is anchored at a first end to the distal end of the catheter body and at a second end to the drive mechanism. The pullwires of each group are positioned close to one another in the catheter wall to concentrate the forces and cause deflection along the articulating section of the catheter body and diverge away from one another to reach a more separated distribution around a circumference of the catheter body to distribute the forces and prevent deflection along the non-articulating section.

Drive systems and methods of use are disclosed herein for performing medical procedures on a patient. The drive systems include various handle types and triggers for controlling catheters and end effectors. The various handle types include a flexible handle and ambidextrous handles that can alter the handedness of the handle for particularized use. The handles drive articulation sections of the catheter and end effectors with various degrees of freedom, and include locks for holding the catheter and/or end effector in place. The catheter systems include structures for allowing degrees of freedom, such as notches, mechanical interlocks, and articulation joints. In addition, the catheters articulate via cables or fluids.

A surgical instrument is described that includes a surgical effector moving with N degrees of freedom for manipulation of objects at a surgical site during surgical procedures. The surgical effector can be manipulated by actuating a first input controller to control a length of a first cable segment to move the surgical effector in at least one degree of freedom of movement and actuating a second input controller to control a length of a second cable segment to move the surgical effector in the at least one degree of freedom of movement. The surgical effector can be manipulated by moving a differential that couples the first and second input controllers together to conserve a length of cable between the first input controller and the second input controller.

A method of manufacturing a surgical instrument mountable to a remotely controllable manipulator configured to operate the surgical instrument includes applying a first tension to a first tensioning element, applying a second tension to a second tensioning element, and maintaining the first and second tensions in the first and second tensioning elements while a first rotatable cylinder is locked to a second rotatable cylinder. The first tensioning element and the second tensioning element are each coupled to a distal end component of the surgical instrument and are coupled to one another such that a tension in one of the first tensioning element and the second tensioning element is transmitted at least in part to the other of the first tensioning element and the second tensioning element.

Knuckle joint assembly for a medical device support system. The knuckle joint assembly includes a cartridge assembly that includes a cartridge housing and a rotary bearing. The cartridge housing includes a bore having a central axis and a bearing mount in the bore. The rotary bearing is press fitted in the bearing mount and configured to receive axially therethrough a spindle to rotatably support the spindle about the central axis. The knuckle joint assembly includes a retaining clip and a retaining pin. The retaining clip is selectively movable to disengage and engage a groove in a spindle to respectively support or release the spindle along a central axis. The retaining pin is movable between a first position to allow movement of the retaining clip between positions but prevent removal of the retaining clip, and a second position to block movement of the retaining clip from the engaged position.

Provided is a flexible mechanism. The flexible mechanism comprises: a flexible backbone which is introduced into a treatment area in the human body and which bends along a path in the human body; and a wire for transmitting an operation force provided through a handler prepared at one end of the flexible backbone to an end-effector prepared at the other end of the flexible backbone, wherein the wire extends from the one end of the flexible backbone to the other end of the flexible backbone and can wind around the outer circumferential surface of the flexible backbone in multiples of 360 degrees or passes through a spiral path formed on an inner surface in multiples of 360 degrees.

A medical instrument system includes actuators, a medical instrument, and a control system operably connected to the actuators. The medical instrument includes an end portion and transmission systems, each of which couples the end portion to an actuator of the actuators such that the actuators are operable to drive the transmission systems to move the end portion. The control system is configured to execute operations including determining a difference between a current configuration of the end portion and a desired configuration of the end portion, and operating the actuators to apply tensions to the transmission systems based on the difference and based on constant offset tensions. The constant offset tensions are independent of current tensions experienced by the transmission systems.

A medical device comprises an end effector, a mechanical structure, a connector, and a force sensor unit. The connector extends from a drive component of the mechanical structure to the end effector. Motion of the drive component produces a tension force within the connector, which is associated with an end effector torque or force exerted by the end effector. The force sensor unit comprises a body, and the body is coupled in-line with the connector so that strain in the connector is imparted to the body. A strain sensor measures the strain on the body as an indication of strain in the connector, which is an indication of torque or force at the end effector. The connector may be continuous, and coupled to the body with a slack relief portion of the connector within the body. Alternatively, the connector may be discontinuous and coupled to opposite ends of the body.

A compliant surgical device such as a flexible entry guide employs tendons to operate or steer the device and attaches asymmetric or constant force spring systems to control tension in the tendons. As a result, the surgical device can be compliant and respond to external forces during a surgical procedure without rapidly springing back or otherwise causing a reaction that damages tissue. The compliance also permits manual positioning or shaping of the device during or before insertion for a surgical procedure without damaging the tendons or connections of the tendons within the device or to a backend mechanism.