Highly articulated robotic probes and methods of production and use of such probes

An articulated probe with a probe central axis, comprising:

• an inner core having a plurality of inner links configured to pivot relative to one another and the probe central axis through an inner maximum pivot angle, wherein the plurality of inner links comprise an inner link channel for receiving an elongated member therein, wherein the inner link channel in each of the inner links is tapered in an amount that permits the inner links to pivot through the inner maximum pivot angle while providing a substantially continuous surface between the inner link channels of the inner links;
• and
• an outer sleeve having a plurality of outer links configured to pivot relative to one another and the probe central axis through an outer maximum pivot angle, wherein the inner links are structurally different than the outer links, wherein only the outer links of the inner and outer links include an outwardly extending flange;
• wherein the inner maximum pivot angle of the inner links of the inner core is greater than the outer maximum pivot angle of the outer links of the outer sleeve, wherein at least two links of the outer links each includes a tapered first channel for receiving the inner links and that permits the at least one of the inner links or outer links to pivot at the inner maximum pivot angle or outer maximum pivot angle, respectively, while providing the substantially continuous surface between the tapered first channels of the at least two outer links,
• wherein the at least two links of the outer links each includes a plurality of second channels peripheral to the first tapered channel,
• wherein the outer links include at least one distal outer link, and
• wherein a width of the outwardly extending flange of the at least one distal outer link is greater than a width of outwardly extending flanges of other outer links of the outer links.

An articulated probe comprising:

• a plurality of outer links configured to pivot relative to one another through a first maximum pivot angle;
• and
• an elongated member,
• wherein at least two of the plurality of outer links each includes an outer link first portion, an outer link second portion, and a first channel extending through the outer link first and second portions of the outer links,
• wherein a first portion of the first channel in the outer link first portion of each of the at least two of the plurality of outer links is tapered in an amount that permits the plurality of outer links to pivot at the first maximum pivot angle while providing a substantially continuous surface between the first channels of the outer links, wherein the probe in an articulating state has a first radius of curvature relative to a central axis and a second radius of curvature relative to the central axis that is greater than the first radius of curvature, and wherein the substantially continuous surface includes the tapered first portions of the first channels of the outer links extending along the first radius of curvature, the articulated probe further comprising a plurality of inner links that are structurally different than the outer links and configured to pivot relative to one another through a second maximum pivot angle, the plurality of inner links comprising a second channel for receiving an elongated member therein,
• wherein the second channel in each of the inner links is tapered in an amount that permits the inner links to pivot through the second maximum pivot angle while providing a substantially continuous surface between the second channels of the inner links,
• wherein the second maximum pivot angle of the inner links is greater than the first maximum pivot angle of the outer links;
• and
• wherein only the outer links of the inner and outer links have outwardly extending flanges of the outer link second portions,
• wherein the outer links include at least one distal outer link, and
• wherein a width of the outwardly extending flange of the at least one distal outer link is greater than a width of outwardly extending flanges of other outer links of the outer links.