# US 2010/0168752 A1 · Orthopaedic cutting tool having a chemically etched metal insert and method of manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2010/0168752 A1 - Document ID: US20100168752A1 - Status: Published application - Kind: A1 - Application number: 12/345,133 - Filed: 2008-12-29 - Published: 2010-07-01 - Earliest claimed: 2008-12-29 - Inventors: Jon M. Edwards - Web page: https://patentgrep.com/patent/US20100168752A1 ## CPC - A61B 17/1659: {Surgical rasps, files, planes, or scrapers} - A61B 17/155: {Cutting femur} - A61B 17/1615: {Drill bits, i.e. rotating tools extending from a handpiece to contact the worked material} - C23F 1/14: Aqueous compositions - A61B 17/157: {Cutting tibia} - A61B 17/1668: {for the upper femur (A61B17/164 takes precedence)} - A61B 2017/00526: {Methods of manufacturing} - A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D) - C23F: NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE (working metal by laser beams B23K26/00; desurfacing by applying flames B23K7/00; working of metal by electro-erosion B23H; producing decorative effects by removing surface material, e.g. by engraving, by etching, B44C1/22; electrolytic etching or polishing C25F); INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25 ## Abstract An orthopaedic surgical instrument comprising an orthopaedic cutting tool includes a metallic cutting insert configured to remove portions of a patient's bone and a body molded to the cutting insert. The cutting insert includes a plurality of chemically etched holes, and the body is molded to the cutting insert such that each of the plurality of chemically etched holes is at least partially filled by a portion of the body. The cutting insert may include a plurality of cutting teeth configured to remove portions of the patient's bone. A method of manufacturing an orthopaedic surgical instrument is also disclosed. ## Claims ### Claim 1 An orthopaedic cutting tool, comprising: a metallic cutting insert having a plurality of chemically etched holes, the cutting insert being configured to remove portions of a patient's bone; and a body molded to the cutting insert such that each of the plurality of chemically etched holes is at least partially filled by a portion of the body. ### Claim 2 (depends on 1) The orthopaedic cutting tool of claim 1, wherein: the cutting insert has (i) an interface surface which contacts the body, and (ii) a work surface opposite the interface surface, the work surface configured to remove portions of the patient's bone; and each of the plurality of chemically etched holes extends from the interface surface to the work surface of the cutting insert. ### Claim 3 (depends on 2) The orthopaedic cutting tool of claim 2, wherein the portion of the body which at least partially fills each chemically etched hole fills at least half the volume of the hole. ### Claim 4 (depends on 1) The orthopaedic cutting tool of claim 1, wherein the cutting insert has (i) a plurality of cutting teeth configured to remove portions of the patient's bone, (ii) at least one relief surface between the plurality of cutting teeth, and (iii) an interface surface opposite the plurality of cutting teeth and the at least one relief surface, the interface surface contacting the body. ### Claim 5 (depends on 4) The orthopaedic cutting tool of claim 4, wherein each of the plurality of chemically etched holes extends from the interface surface to the at least one relief surface of the cutting insert. ### Claim 6 (depends on 5) The orthopaedic cutting tool of claim 5, wherein the portion of the body which at least partially fills each chemically etched hole fills at least half the volume of the hole. ### Claim 7 (depends on 1) The orthopaedic cutting tool of claim 1, wherein the body includes an integrally formed coupling feature. ### Claim 8 (depends on 1) The orthopaedic cutting tool of claim 1, wherein in the body includes an integrally formed handle portion. ### Claim 9 (depends on 1) The orthopaedic cutting tool of claim 1, wherein the body comprises an injection-molded polymer. ### Claim 10 An orthopaedic surgical instrument, comprising: an orthopaedic cutting tool having (i) a plurality of metallic cutting inserts, each cutting insert having a plurality of chemically etched holes and being configured to remove portions of a patient's bone, and (ii) a body molded to the plurality of cutting inserts such that each of the plurality of chemically etched holes is at least partially filled by a portion of the body. ### Claim 11 (depends on 10) The orthopaedic surgical instrument of claim 10, wherein: each of the plurality of cutting inserts has (i) an interface surface which contacts the body, and (ii) a work surface opposite the interface surface, the work surface configured to remove portions of the patient's bone; and each of the plurality of chemically etched holes extends from the interface surface to the work surface of the respective cutting insert. ### Claim 12 (depends on 10) The orthopaedic surgical instrument of claim 10, wherein: the body includes a plurality of cutting flutes, the plurality of cutting flutes arranged radially outward around a longitudinal axis of the orthopaedic cutting tool; and each of the plurality of cutting inserts is disposed on one of the plurality of cutting flutes. ### Claim 13 (depends on 12) The orthopaedic surgical instrument of claim 12, wherein each of the plurality of cutting inserts is aligned with a leading edge of one of the plurality of cutting flutes to allow a surgeon to remove portions of the patient's bone by rotating the orthopaedic cutting tool about the longitudinal axis. ### Claim 14 A method for manufacturing an orthopaedic surgical instrument, the method comprising: chemically etching a plurality of holes into a metallic cutting insert; and molding a body to the cutting insert to form an orthopaedic cutting tool. ### Claim 15 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein chemically etching the plurality of holes into the cutting insert comprises chemically etching each of the plurality of holes through the entire thickness of the cutting insert. ### Claim 16 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein chemically etching the plurality of holes into the cutting insert comprises: forming a mask on the cutting insert, the mask defining a plurality of exposed areas; placing the cutting insert having the mask in a chemical bath whereby the plurality of exposed areas are chemically etched into the plurality of holes; removing the cutting insert having the mask from the chemical bath; and removing the mask from the cutting insert. ### Claim 17 (depends on 16) The method for manufacturing an orthopaedic surgical instrument of claim 16, wherein forming the mask on the cutting insert comprises: applying a photoresist material to the cutting insert; selectively exposing portions of the photoresist material to a light source using a patterned photomask; and selectively removing portions of the photoresist material using a developer to define the plurality of exposed areas on the cutting insert. ### Claim 18 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein molding the body to the cutting insert comprises: loading the cutting insert into a mold, the cutting insert contacting a wall of the mold; and injecting a polymer into the mold such that the cutting insert is pressed against the wall of the mold by the polymer and the polymer at least partially fills the plurality of holes. ### Claim 19 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, further comprising chemically etching a plurality of cutting teeth into the cutting insert. ### Claim 20 (depends on 19) The method for manufacturing an orthopaedic surgical instrument of claim 19, wherein the plurality of holes and the plurality of cutting teeth are chemically etched simultaneously.