Flexible drive shaft assembly and methods

A method of manufacturing an orthopedic tool for preparing a bone, the method comprising:

• providing or receiving a coupling member to a mold, the coupling member adapted for attachment to a torque-providing driving tool;
• providing or receiving a work member to the mold, the work member adapted to interface with the bone to prepare the bone;
• and
• injecting a polymeric material into the mold to form a flexible shaft extending from a first overmold connection to the coupling member at a first end portion of the flexible shaft to a second overmold connection to the work member at a second end portion of the flexible shaft;
• wherein the flexible shaft is adapted to transmit a majority of a rotational motion and torque received by the coupling member from the torque-providing driving tool through the flexible shaft to the work member.

A flexible orthopedic tool for preparing a bone of a patient, the flexible orthopedic tool comprising:

• a flexible shaft having a length extending from a first end portion to a second end portion, the flexible shaft comprising a polymeric material adapted to bend into a curved shape;
• a coupling member coupled to the first end portion, the coupling member adapted for attachment to a torque-providing driving tool, the coupling member adapted to receive a rotational motion and torque from the torque-providing driving tool and to transmit the rotational motion and torque through the flexible shaft;
• and
• a work member coupled to the second end portion, the work member adapted to receive the rotational motion and torque from the flexible shaft and to interface with the bone or a work element configured to prepare the bone,
• wherein the polymeric material is adapted to carry and transmit substantially all of the rotational motion and torque from the coupling member to the work member.