A sensor includes: a tubular needle member that includes a side wall and defines a hollow portion; and a linear detection member located in the hollow portion. The side wall of the needle member includes a thick portion that is thicker than another portion of the side wall in a cross-section of the needle member, and wherein the thick portion protrudes toward the hollow portion.

A needle bender for custom bending of needles to different desired needle bend radii is provided. The needle bender can include abase and a shaper coupled to the base through a support member. The shaper may have a plurality of grooves corresponding to different desired needle bend radii. A leverage arm with a needle slide disposed on one end may be rotatably coupled to the support arm. When a needle is inserted along the base into one of the grooves in the shaper and at least partially into the needle slide, the leverage arm can be actuated toward the base to thereby bend the needle to the desired needle bend radius. The needle bender may also include a lock plate between the base and the shaper that can be actuated toward the shaper to further secure the needle to the shaper.

A needle bender for custom bending of needles to different desired needle bend radii is provided. The needle bender can include abase and a shaper coupled to the base through a support member. The shaper may have a plurality of grooves corresponding to different desired needle bend radii. A leverage arm with a needle slide disposed on one end may be rotatably coupled to the support arm. When a needle is inserted along the base into one of the grooves in the shaper and at least partially into the needle slide, the leverage arm can be actuated toward the base to thereby bend the needle to the desired needle bend radius. The needle bender may also include a lock plate between the base and the shaper that can be actuated toward the shaper to further secure the needle to the shaper.

A method of manufacturing a plunger of a drug delivery device includes forming a plunger body. The method includes loading the plunger body into a cavity of a first molding tool of a molding system. The cavity is at least partially defined by a first molding portion and a second molding portion. The method includes coupling a second molding tool to the first molding tool to form a plurality of channels defined by grooves in the first and second molding tools, and injecting molten plastic into the plurality of channels to form an overmolded plunger body. The overmolded plunger body includes a head coupled to the first end of the plunger body and a foot coupled to the second end of the plunger body. The foot is at least partially coupled to the inner wall and the head is coupled to the outer wall of the plunger body.

A material dispense tip includes an elongated hole in an elongated neck that extends from an input end of the neck to an output end of the neck. The hole at the output end of the neck has a first diameter. The output end of the neck is positioned against a die surface. A punch is inserted into the hole at the input end of the neck. An external force is applied to the neck to cause the output end of the neck to be deformed under compression by the die surface, to reduce the diameter of the hole at the output end of the neck from the first diameter to a second diameter that is less than the first diameter.

Systems and methods are disclosed for bending a needle. A device for bending a needle is disposed around a needle and coupled to an injection device. A force is exerted on the needle to cause the needle to bend upon a bending trough of the device. The device includes a proximal end to interface with the injection device and a distal end having the bending trough. The bending trough is configured to improve bending and prevent breaking of the needle by providing a rounded surface upon which the needle is bent.

Embodiments of assemblies used for bending spinal needles and method for producing bent spinal needles used in medical procedures are disclosed. In one embodiment, a straight needle is placed in position for a fulcrum to apply pressure onto a designated spot on the needle and apply a bending pressure to bend the needle while the needle is supported at both ends. A barrier wall is configured to limit the movement of the needle resulting from the bending force to prevent overbending of the needle. In two other embodiments, a dual angle bending member enables selecting the bending angle desired by the user to be applied onto the needle. The angle of the bent needle is considerably reduced due to metal relaxation; however, the angle reduction is predictable and is taken into account in calculating the target bending angle.

A medical puncture needle includes an end portion including a needle tip; and a main body portion contiguous with the end portion, having a substantially circular cross-sectional outer shape. The end portion includes a first bevel formed by a curved surface, the bevel having an angle that gradually decreases toward the needle tip in an axial direction, in a cross-section orthogonal to the axial direction, relative to an imaginary plane that extends along an axis of the main body portion.

A medical puncture needle includes an end portion including a needle tip; and a main body portion contiguous with the end portion, having a substantially circular cross-sectional outer shape. The end portion includes a first bevel formed by a curved surface, the bevel having an angle that gradually decreases toward the needle tip in an axial direction, in a cross-section orthogonal to the axial direction, relative to an imaginary plane that extends along an axis of the main body portion.

A swaging system for attaching surgical needles to sutures and testing the attachment strength includes a frame, a bottom swaging die mounted on the frame, and a top swaging die mounted on the frame and being moveable up and down along a swaging axis that is aligned with the bottom swaging die. The bottom swaging die includes a hinge mechanism with a bottom plate mounted to the frame and a top plate overlying the bottom plate. The top and bottom plates are pivotally connected for enabling the top plate to pivot relative to the bottom plate. The bottom swaging die includes a swaging tool that extends toward the top swaging die along the swaging axis, and a load cell disposed between the top and bottom plates for monitoring load. The system includes a control system having one or more pull test programs stored therein for conducting pull tests on armed surgical needles to determine if the armed surgical needles are acceptable or unacceptable.