Exploring non-assembly 3D printing for novel compliant surgical devices

Area of Science:

• Medical Devices
• Robotics
• Additive Manufacturing

Background:

• Minimally invasive surgery demands high maneuverability, often limited by complex instruments with many degrees of freedom (DOF).
• Increasing DOF typically increases instrument complexity, fabrication, and assembly times.

Purpose of the Study:

• To introduce the first fully 3D-printed, handheld, multi-steerable surgical device.
• To demonstrate a novel compliant segment design merging functions for improved stiffness and flexibility.
• To showcase additive manufacturing's potential for creating complex surgical instruments.

Main Methods:

• Designed a novel compliant segment with high torsion/axial stiffness and low bending stiffness using merged helicoid and continuum backbone structures.
• Constructed a mechanically actuated device with five serially controlled segments and a matching control handle.
• Fabricated a prototype, HelicoFlex, using only three 3D-printed parts, including a compliant shaft printed without internal support material.

Main Results:

• The HelicoFlex prototype demonstrated 10 degrees of freedom with fluid motion capabilities.
• The device successfully performed both single and multi-curved paths.
• The 3D printing process for the compliant shaft was achieved without support material.

Conclusions:

• The HelicoFlex represents a significant advancement in 3D-printed, multi-steerable surgical instruments.
• Additive manufacturing enables the efficient production of complex surgical tools with enhanced dexterity.
• This technology holds promise for applications in personalized medicine and advanced surgical procedures.