A method is used to manufacture a knife of an end effector of a surgical instrument. The method includes forming the knife using metal injection molding. The knife has at least one feature having a molded shape. The method also includes machining the at least one feature of the knife to have a machined shape without machining the entire knife. The method also includes incorporating the knife into the end effector of the surgical instrument.

A method is used to manufacture a knife of an end effector of a surgical instrument. The method includes forming the knife using metal injection molding. The knife has at least one feature having a molded shape. The method also includes machining the at least one feature of the knife to have a machined shape without machining the entire knife. The method also includes incorporating the knife into the end effector of the surgical instrument.

A cutting tool, such as a kitchen knife, has a handle with an outer grip surface. A blade extends from a distal end of the handle along a central axis. The blade is formed of a metal material and has opposing first and second side surfaces that converge to a cutting edge having a plurality of continuous segments separated by a series of spaced-apart channels. Each channel is formed by an interior sidewall that extends into a body portion of the blade from the first side surface to the second side surface. Each of the channels has a channel width extending in a direction along the cutting edge, and a channel depth orthogonal to the channel width. The channels are formed using a cold forging operation on the first side surface to provide localized work hardened portions of the metal material adjacent the respective channels.

A cutting tool, such as a kitchen knife, has a handle with an outer grip surface. A blade extends from a distal end of the handle along a central axis. The blade is formed of a metal material and has opposing first and second side surfaces that converge to a cutting edge having a plurality of continuous segments separated by a series of spaced-apart channels. Each channel is formed by an interior sidewall that extends into a body portion of the blade from the first side surface to the second side surface. Each of the channels has a channel width extending in a direction along the cutting edge, and a channel depth orthogonal to the channel width. The channels are formed using a cold forging operation on the first side surface to provide localized work hardened portions of the metal material adjacent the respective channels.

The present invention relates to a cutting blade such as a kitchen knife blade. The cutting blade comprises a cutting edge, a spine and opposite side surfaces. A tapered portion of the blade extends longitudinally and adjacent to the cutting edge in which a thickness of the blade defined as a transverse distance between the opposite side surfaces tapers towards the cutting edge. The cutting blade includes one or more broad recesses provided in one or more side surfaces of the blade, wherein at least one of the broad recesses is bounded at vertically opposite sides by the tapered portion and the spine and at longitudinally opposite sides by narrow supporting elements extending from the spine to the tapered portion. Embodiments of the cutting blade have a substantially reduced average wedge thickness which reduces cutting resistance to due to the wedging effect. Embodiments of the cutting blade provide a reduced total surface area of the one or more sides surfaces in contact with an item being cut by the blade which reduces cutting resistance due to friction between the side surfaces of the blade and the item. The present invention also provides for methods of forming a cutting blade, such as by near-net or additive manufacturing techniques.

The present invention relates to a cutting blade such as a kitchen knife blade. The cutting blade comprises a cutting edge, a spine and opposite side surfaces. A tapered portion of the blade extends longitudinally and adjacent to the cutting edge in which a thickness of the blade defined as a transverse distance between the opposite side surfaces tapers towards the cutting edge. The cutting blade includes one or more broad recesses provided in one or more side surfaces of the blade, wherein at least one of the broad recesses is bounded at vertically opposite sides by the tapered portion and the spine and at longitudinally opposite sides by narrow supporting elements extending from the spine to the tapered portion. Embodiments of the cutting blade have a substantially reduced average wedge thickness which reduces cutting resistance to due to the wedging effect. Embodiments of the cutting blade provide a reduced total surface area of the one or more sides surfaces in contact with an item being cut by the blade which reduces cutting resistance due to friction between the side surfaces of the blade and the item. The present invention also provides for methods of forming a cutting blade, such as by near-net or additive manufacturing techniques.

Apparatus and method for sharpening a cutting tool so as to have enhanced cutting performance. In some embodiments, a tool sharpener is provided having a rigid body with a slot extending therein. A knurl roller is disposed within an internal cavity within the rigid body and mounted for rotation about a selected axis adjacent the slot to facilitate a cold forging operation upon a cutting edge of a cutting tool via insertion of the cutting edge into the slot and retraction of the cutting tool across the knurl roller. An abrasive member is affixed to the rigid body to facilitate a sharpening operation upon the cutting edge by advancement of the cutting edge thereacross.

Apparatus and method for sharpening a cutting tool so as to have enhanced cutting performance. In some embodiments, a tool sharpener is provided having a rigid body with a slot extending therein. A knurl roller is disposed within an internal cavity within the rigid body and mounted for rotation about a selected axis adjacent the slot to facilitate a cold forging operation upon a cutting edge of a cutting tool via insertion of the cutting edge into the slot and retraction of the cutting tool across the knurl roller. An abrasive member is affixed to the rigid body to facilitate a sharpening operation upon the cutting edge by advancement of the cutting edge thereacross.

A futuristic shoe with true energy return based on enhanced heel-lift, optimized shoe springs (40% reduction in maximum foot impact), practical precise automatic electronic gear changers, novel powerful shoe impact chargers, improved pulley electronic actuators, novel low-impact much stronger springs (featuring the novel use materials such as Kevlar, Spectra Shield, and fiberglass), novel remarkably stronger, more flexible, and tougher structures, and multiple designs for enhanced heel-lift and to prevent excessive toe sink. These designs require linkages and two improved hingesone with enhanced natural hinges and a second with tied cogged hinges. There is a rotating-arms enhanced optimal spring, which when combined with the tied cogged hinges, results in optimal foldable arrays for deployment in outer spaceand which gives a smart energy return knee brace. These novel capabilities promise a wide range of additional applications such as robotics, prosthetics, orthotics, springs, aerospace, automobiles, body armor, and earthquake retrofitting.

A futuristic shoe with true energy return based on enhanced heel-lift, optimized shoe springs (40% reduction in maximum foot impact), practical precise automatic electronic gear changers, novel powerful shoe impact chargers, improved pulley electronic actuators, novel low-impact much stronger springs (featuring the novel use materials such as Kevlar, Spectra Shield, and fiberglass), novel remarkably stronger, more flexible, and tougher structures, and multiple designs for enhanced heel-lift and to prevent excessive toe sink. These designs require linkages and two improved hingesone with enhanced natural hinges and a second with tied cogged hinges. There is a rotating-arms enhanced optimal spring, which when combined with the tied cogged hinges, results in optimal foldable arrays for deployment in outer spaceand which gives a smart energy return knee brace. These novel capabilities promise a wide range of additional applications such as robotics, prosthetics, orthotics, springs, aerospace, automobiles, body armor, and earthquake retrofitting.