Highly maneuverable surgical catheter and bronchoscope

A method of producing a multi-stage catheter device for traversing internal body passages;

• said device comprising:
• a distal stage hollow catheter and a different proximal stage hollow catheter;
• said distal stage hollow catheter being a rotating distal stage hollow catheter with a distal stage axis that is configured to rotate about a proximal stage axis of said different proximal stage hollow catheter, one end of said rotating distal stage hollow catheter affixed to an end of said different proximal stage hollow catheter by a transition point coupler;
• said transition point coupler configured to traverse an internal body passage;
• said transition point coupler comprising a transition housing that includes a hollow rotatable coupler, said hollow rotatable coupler configured to act as a rotary joint to enable said one end of said rotating distal stage hollow catheter to rotate about said end of said different proximal stage hollow catheter;
• said device further comprising a hollow torque shaft mounted inside said proximal stage hollow catheter and attached to said hollow rotatable coupler, said hollow torque shaft configured to convey torque to said rotatable coupler and said rotating distal stage hollow catheter;
• said device further comprising at least one proximal stage steering cable connected to said transition housing, said at least one proximal stage steering cable disposed inside said proximal stage hollow catheter, outside said hollow torque shaft, said at least one proximal stage steering cable enabled to convey proximal stage steering force on said transition housing, causing said transition housing and said distal stage hollow catheter to move according to said proximal stage steering force;
• said hollow torque shaft, rotating distal stage hollow catheter, hollow rotatable coupler and said transition housing further comprising a working channel configured to convey a plurality of conduits through said proximal stage hollow catheter and said rotating distal stage hollow catheter to at least a distal tool plate mounted on a distal end of said rotating distal stage hollow catheter;
• wherein at least some of said conduits comprise at least one distal stage steering cable connected to said distal tool plate on said distal end of said rotating distal stage hollow catheter;
• said at least one distal stage steering cable enabled to convey distal stage steering force on said distal tool plate, causing said distal tool plate and said rotating distal stage catheter to further move according to said distal stage steering force;
• said method comprising scanning a patient, obtaining lumen pathway data;
• using at least one design processor to determine fabrication instructions;
• and
• using said fabrication instructions to construct at least portions of said multi-stage catheter device.

A multi-stage catheter device, said device comprising:

• a distal stage hollow catheter and a proximal stage hollow catheter, one end of said distal stage hollow catheter affixed to an end of said proximal stage hollow catheter by a hollow rotatable coupler and transition housing configured to enable said one end of said distal stage hollow catheter to rotate with respect to said end of said proximal stage hollow catheter;
• said device further comprising a hollow torque shaft mounted inside said proximal stage hollow catheter, said hollow torque shaft configured to convey torque to said distal stage hollow catheter;
• said device further comprising at least one proximal stage steering cable connected to said transition housing, said at least one proximal stage steering cable disposed inside said proximal stage hollow catheter, outside said hollow torque shaft, said at least one proximal stage steering cable enabled to convey proximal stage steering force on said transition housing, causing said transition housing and said distal stage hollow catheter to move according to said proximal stage steering force;
• said hollow torque shaft, distal stage hollow catheter, hollow rotatable coupler and said transition housing further comprising a working channel configured to convey a plurality of conduits through said proximal stage hollow catheter and said distal stage hollow catheter to at least a distal tool plate mounted on a distal end of said distal stage hollow catheter;
• wherein at least some of said conduits comprise at least one distal stage steering cable connected to said distal tool plate on said distal end of said distal stage hollow catheter;
• said at least one distal stage steering cable enabled to convey distal stage steering force on said distal tool plate, causing said distal tool plate and said distal stage catheter to further move according to said distal stage steering force;
• wherein said device further comprises a computerized motor actuator system configured to apply variable torque to said hollow torque shaft, and variable tension to any of said at least one proximal stage steering cable and/or at least one distal stage steering cable;
• and
• wherein said computerized motor actuator system is configured to operate according to an algorithm to reduce friction, while still guiding said catheter to a desired location, by repetitively lowering said variable tension to reduce friction, applying said torque to partially rotate said distal stage hollow catheter, and then reestablishing tension to guide said catheter to said desired location.