A staple cartridge assembly for use with a surgical stapling instrument includes a staple cartridge including a plurality of staples and a cartridge deck. The staple cartridge assembly also includes a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises a first biocompatible layer comprising a first portion, a second biocompatible layer comprising a second portion, and crossed spacer fibers extending between the first portion and the second portion.

Foamed articles including a foamed thermoplastic elastomeric material, methods of making the articles, and methods for manufacturing articles of footwear, apparel, and athletic equipment incorporating the articles are provided. One exemplary method for making a foamed article comprises placing an article comprising a foamable fibrous element and carbon dioxide in a vessel, the foamable fibrous element comprising a plurality of filaments, fibers, and/or yarns, wherein each member of the plurality comprises a foamable material; maintaining the vessel at a first pressure and first temperature at which the carbon dioxide is a liquid and carbon dioxide is soluble in the foamable material; optionally exposing the infused article to a second temperature and second pressure; and subjecting the article to a third pressure and third temperature at which the infused carbon dioxide phase transitions to a gas, thereby expanding the foamable material into a foamed material and forming the foamed article.

A surgical stapling instrument including staples and an implantable layer is disclosed. The implantable layer comprises fibers which have undergone a kinking process. The kinked fibers, once interwoven together, create a resilient body that can dynamically adapt to the thickness of the tissue captured within the staples.

A staple cartridge assembly for use with a surgical stapling instrument includes a staple cartridge including a plurality of staples and a cartridge deck. The staple cartridge assembly also includes a compressible adjunct positionable against the cartridge deck, wherein the staples are deployable into tissue captured against the compressible adjunct, and wherein the compressible adjunct comprises a first biocompatible layer comprising a first portion, a second biocompatible layer comprising a second portion, and crossed spacer fibers extending between the first portion and the second portion.

A surgical instrument includes a jaw member having a slot, a first outer surface on a first side of the slot, and a second outer surface on a second side of the slot opposite the first side. The surgical instrument includes an adjunct assembly having an attachment layer including a first section on the first side of the slot attached to the first outer surface, a second section on the second side of the slot attached to the second outer surface, and an intermediary section extending between the first section and the second section, the intermediary section at least partially bridging the slot. The adjunct assembly further includes a first compressible adjunct on the first side and a second compressible adjunct on the second side, the compressible adjuncts spaced apart, the first section attached to the first compressible adjunct, and the second section attached to the second compressible adjunct.

A method for forming a molded fiber product includes forming a layer of foam including fibers, water, air and foaming chemical by a pair of molds. In addition, in the method, foam is fed between the molds, and the pair is closed and opened. Foam is fed via one of the molds while the pair is sealed from its sides.

A compressible adjunct has a first portion, a second portion, and a middle portion. The middle portion is disposed between the first portion and the second portion. The middle portion comprises a first pillar, a second pillar, and an interconnecting member. The first pillar and the second pillar extend substantially between the first portion and the second portion. The interconnecting member is configured to engage at least the first pillar and the second pillar. When the compressible adjunct is compressed by a force, the first pillar is configured to deflect a first deflection and the second pillar is configured to deflect a second deflection. The first deflection differs from the second deflection.

A staple cartridge assembly comprising an implantable layer is disclosed. The implantable layer comprises a top portion, a bottom portion, and structural walls interwoven between the top portion and the bottom portion.

A foaming process for converting fibrous material into a cellular foam structure includes mixing fibrous material and a solvent-based binding agent to form a mixture; saturating the mixture with a pressurized gas to form a gas-saturated mixture; expanding the gas-saturated mixture by reducing the pressure of the pressurized gas to form an expanded mixture with voids in the fibrous material; and curing the expanded mixture to set the fibrous material and drive off the solvent to provide a stable network of fibrous material having cushioning properties.

A staple cartridge assembly is used with a surgical stapler. The staple cartridge assembly includes a staple cartridge including a cartridge body, a cartridge deck, and a plurality of staples deployable from the cartridge body through the cartridge deck. The staple cartridge assembly includes a compressible adjunct positionable against the cartridge deck. The compressible adjunct includes a plurality of unaltered fibers and a plurality of altered fibers that are melted and resolidified. The unaltered fibers include a first fiber including a first fiber portion and a second fiber including a second fiber portion extending over the first fiber portion. The compressible adjunct further includes a node which comprises the first fiber portion, the second fiber portion, and at least a portion of the plurality of altered fibers, wherein the at least a portion of the plurality of altered fibers affixes the first fiber portion and the second fiber portion.