Ultrasonic surgical instrument with ad hoc formed blade

A method of forming a component of an ultrasonic surgical instrument at a clinical facility, the method comprising:

• (a) accessing a set of modeling data associated with the component, wherein the set of modeling data comprises:
• (i) a distal portion comprising an ultrasonic blade, and
• (ii) a proximal portion configured to transmit ultrasonic vibrations to the ultrasonic blade when the proximal portion is secured to a complementary portion of the ultrasonic surgical instrument;
• and
• (b) fabricating the component via an additive manufacturing process using the set of modeling data.

A system for ad hoc manufacturing of medical device components at a clinical facility, comprising:

• (a) a clinical facility system comprising a processor and a memory;
• (b) an additive manufacturing device located at the clinical facility and communicatively coupled with the clinical facility system;
• wherein the processor of the clinical facility system is configured to:
• (i) determine a component to be produced based upon an input;
• (ii) access a set of modeling data associated with the component, wherein the set of modeling data comprises:
• (A) a distal portion comprising an ultrasonic blade, and
• (B) a proximal portion configured to transmit ultrasonic vibrations to the ultrasonic blade when the proximal portion is secured to a complementary portion of an ultrasonic surgical instrument;
• and
• (iii) provide the set of modeling data to the additive manufacturing device;
• wherein the additive manufacturing device is configured to fabricate the component based on the set of modeling data.

A clinical facility system for ad hoc manufacturing of medical device components at a clinical facility, comprising a processor and a memory, the processor configured to:

• (a) determine a component of an ultrasonic surgical instrument to be produced based on a user input;
• (b) access a set of modeling data associated with the component, wherein the set of modeling data comprises:
• (i) a distal portion comprising an ultrasonic blade, and
• (ii) a proximal portion configured to transmit ultrasonic vibrations to the ultrasonic blade when the proximal portion is secured to a complementary portion of the ultrasonic surgical instrument;
• and
• (c) provide the set of modeling data to an additive manufacturing device at a clinical facility;
• wherein the set of modeling data is usable by the additive manufacturing device to fabricate the component.