A method for moulding an elongate articulated bending section body (4) for a medical device including a number of segments (7) interconnected via a number of hinge members (8). The method includes the use of a mould having a first number of sub-cavities where each of the sub-cavities has at least one external fluid inlet through which a liquified plastic material is injected into the mould. The sub-cavities are so distributed that each sub-cavity is separated from another sub-cavity by an odd number of sub-cavities without an external fluid inlet.

A surgical instrument system including an endoscope having an elongated housing extending between a proximal instrument end and a distal instrument end. The surgical instrument system may further include an irrigation sleeve having a sleeve body extending between a proximal sleeve end and a distal sleeve end. The irrigation sleeve may further have a first lumen and a second lumen spaced out of fluid communication with the first lumen, the first lumen formed in the sleeve body for receiving at least a portion of the elongated housing of the endoscope with the distal instrument end arranged adjacent to the distal sleeve end. The second lumen may be formed in the sleeve body and extend between a lumen inlet adapted for fluid communication with an irrigation source and a lumen outlet arranged to direct irrigation fluid toward the distal instrument end.

A method of fabricating an ultrasonic medical device is presented. The method includes machining a surgical tool from a flat metal stock, contacting a face of a first transducer with a first face of the surgical tool, and contacting a face of a second transducer with an opposing face of the surgical tool opposite the first transducer. The first and second transducers are configured to operate in a D31 mode with respect to the longitudinal portion of the surgical tool. Upon activation, the first transducer and the second transducer are configured to induce a standing wave in the surgical tool and the induced standing wave comprises a node at a node location in the surgical tool and an antinode at an antinode location in the surgical tool.

A bone fixation device made of polysaccharide particles or microspheres fused into a solid structure is provided herein. The bone fixation device may be in the form of an orthopedic screw, orthopedic pin, or orthopedic plate. Methods of making the bone fixation devices described herein are provided as are methods of treating patients in need of bone repair or replacement by implanting a bone fixation device described herein in the patient at a site of bone damage, ligament damage, or bone deformity.

Described is a medical device lead including a lead body having a conductor lumen including an inner surface. The lead also includes a conductor assembly extending through the conductor lumen; the conductor assembly comprising a conductor member and an outer insulative layer; and an electrode coupled to the conductor cable. The outer insulative layer includes a textured external surface that reduces the coefficient of friction between the outer insulative layer and the inner surface of the conductor lumen through which the conductor assembly extends. Methods of forming the conductor assembly are also described.

A system for making a customized orthopedic surgical instrument for use in repairing a joint of a patient includes a computer system for generating computer-readable instructions to form a patient-specific orthopedic surgical instrument based at least in part on image data obtained from at least a portion of a bone corresponding to the joint of the patient; and a machine for forming a patient-specific orthopedic surgical instrument from the computer-readable instructions. The surgical instrument includes a resin composition including from about 50 wt % to about 90 wt % of a base thermoplastic and from about 10 wt % to about 50 wt % of a filler material. The base thermoplastic includes polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof. The surgical instrument includes at least one surface portion having a shape that substantially conforms to a corresponding surface portion of the bone.

An orthopedic surgical instrument includes from about 40 wt % to about 85 wt % of a base thermoplastic and from about 15 wt % to about 60 wt % of a filler material. The base thermoplastic includes polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof. In some aspects all materials in the orthopedic surgical instrument are biocompatible. An orthopedic surgical kit includes an orthopedic surgical instrument and a container suitable for sealing the orthopedic surgical instrument therein. The orthopedic surgical instrument in the kit includes from about 50 wt % to about 90 wt % of a base thermoplastic selected from the group consisting of polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof, and from about 10 wt % to about 50 wt % of a filler material.

An electrode assembly comprises an electrode support, an electrode on the electrode support, the electrode having a working surface extending generally transverse to a thickness of the electrode, and a filament of electrically insulative material overlying a portion of the working surface of the electrode and at least partially extending through the thickness of the electrode. An electrosurgical may include an end effector having a jaw member comprising such an electrode assembly.

Generally, a sterile adapter for use in robotic surgery may include a frame configured to be interposed between a tool driver and a surgical tool, a plate assembly coupled to the frame, and at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool.

Generally, a system for use in a robotic surgical system may be used to determine an attachment state between a tool driver, sterile adapter, and surgical tool of the system. The system may include sensors used to generate attachment data corresponding to the attachment state. The attachment state may be used to control operation of the tool driver and surgical tool. In some variations, one or more of the attachment states may be visually output to an operator using one or more of the tool driver, sterile adapter, and surgical tool. In some variations, the tool driver and surgical tool may include electronic communication devices configured to be in close proximity when the surgical tool is attached to the sterile adapter and tool driver.