# US 2019/0167294 A1 · Ultrasonic surgical instrument with ad hoc formed blade > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0167294 A1 - Document ID: US20190167294A1 - Status: Published application - Kind: A1 - Application number: 16/211,429 - Filed: 2018-12-06 - Published: 2019-06-06 - Earliest claimed: 2016-07-12 - Assignees: Ethicon, Inc. - Applicants: Ethicon LLC - Inventors: Sean P. Conlon - Web page: https://patentgrep.com/patent/US20190167294A1 ## CPC - A61B 17/320068: {using mechanical vibrations, e.g. ultrasonic (A61B17/22012 takes precedence; dental tooth drilling devices operated by vibration A61C3/03; removing intra-ocular material using mechanical vibrations A61F9/00745)} - A61B 17/320092: {with additional movable means for clamping or cutting tissue, e.g. with a pivoting jaw} - A61N 7/00: Ultrasound therapy (lithotripsy A61B17/22, A61B17/225; massage using supersonic vibration A61H23/00 {; using ultrasound for introducing media into the body A61M37/0092}) - B22F 5/00: Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B23K 26/342: Build-up welding - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - A61B 17/22012: {in direct contact with, or very close to, the obstruction or concrement (for removing obstructions in blood vessels by laser A61B18/245)} - A61B 2017/00402: {Piezo electric actuators} - A61B 2017/00424: {ergonomic, e.g. fitting in fist} - A61B 2017/00526: {Methods of manufacturing} - A61B 2017/320071: {with articulating means for working tip} - A61B 2017/320088: {with acoustic insulation, e.g. elements for damping vibrations between horn and surrounding sheath} - A61B 2017/320094: {additional movable means performing clamping operation} - A61B 2017/320095: {with sealing or cauterizing means} - B22F 10/62: by chemical means - B22F 10/66: by mechanical means - B22F 10/68: Cleaning or washing - B22F 10/80: Data acquisition or data processing - B33Y 50/00: Data acquisition or data processing for additive manufacturing - Y02P 10/25: Process efficiency - A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D) - A61N: ELECTROTHERAPY; MAGNETOTHERAPY; RADIATION THERAPY; ULTRASOUND THERAPY (measurement of bioelectric currents A61B; surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body A61B18/00; anaesthetic apparatus in general A61M; incandescent lamps H01K; infrared radiators for heating H05B) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method of forming a component of an ultrasonic surgical instrument includes accessing a file including a digital model representing the component. The component includes a proximal portion and a distal portion. The proximal portion includes a contact portion. The distal portion includes an ultrasonic blade. The contact portion is configured to transmit ultrasonic vibrations to the ultrasonic blade when the component is acoustically coupled to a complementary portion of an acoustic waveguide of the ultrasonic surgical instrument. The file is used to fabricate the component via an additive manufacturing process. Once the component has been fabricated, the distal portion is secured to a distal end of the complementary portion of the acoustic waveguide. ## Claims ### Claim at position 1 1-20. (canceled) ### Claim 21 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. ### Claim 22 (depends on 21) The method of claim 21, further comprising using the component during a surgical procedure at the clinical facility, wherein: (i) the proximal portion comprises a contact portion, (ii) the contact portion comprises a predetermined surface roughness, and (iii) the predetermined surface roughness is configured to enable the ultrasonic blade to vibrate at a predetermined vibratory frequency in response to the ultrasonic vibrations transmitted from a transducer when the proximal portion is acoustically coupled to the complementary portion. ### Claim 23 (depends on 22) The method of claim 22, further comprising: (a) providing the component and at least a portion of the set of modeling data to a machining device at the clinical facility; and (b) operating the machining device to machine the contact portion of the component to the predetermined surface roughness based on the set of modeling data. ### Claim 24 (depends on 21) The method of claim 21, wherein accessing the set of modeling data comprises receiving the set of modeling data from a remote server. ### Claim 25 (depends on 24) The method of claim 24, wherein the set of modeling data comprises a standard tessellation language (STL) file. ### Claim 26 (depends on 24) The method of claim 24, wherein accessing the set of modeling data comprises obtaining a license to use the set of modeling data for the additive manufacturing process. ### Claim 27 (depends on 21) The method of claim 21, further comprising securing the component to the complementary portion of the ultrasonic surgical instrument. ### Claim 28 (depends on 27) The method of claim 27, wherein securing the component to the complementary portion of the acoustic waveguide comprises threading a threaded protrusion into a threaded recess. ### Claim 29 (depends on 21) The method of claim 21, wherein fabricating the component via the additive manufacturing process comprises providing the set of modeling data to an additive manufacturing system at the clinical facility. ### Claim 30 (depends on 29) The method of claim 29, wherein: (i) the additive manufacturing system comprises a direct metal laser sintering device, and (ii) fabricating the component via the additive manufacturing process comprises utilizing a titanium alloy powder with the direct metal laser sintering device. ### Claim 31 (depends on 21) The method of claim 21, further comprising receiving the ultrasonic surgical instrument at the clinical facility. ### Claim 32 (depends on 31) The method of claim 31, wherein: (i) the ultrasonic surgical instrument includes an initial component when received at the clinical facility, and (ii) the initial component is adapted to be disposed off after use and replaced by the component. ### Claim 33 (depends on 21) The method of claim 21, wherein accessing the set of modeling data comprises: (i) scanning an existing component, wherein the component is a copy of the existing component, and (ii) creating the set of modeling data based on the scan of the existing component. ### Claim 34 (depends on 21) The method of claim 21, further comprising selecting the set of modeling data from a digital catalog. ### Claim 35 (depends on 34) The method of claim 34, wherein selecting the set of modeling data from the digital catalog comprises: (i) providing an identifier associated with the ultrasonic surgical instrument, (ii) receiving a list of components associated with the ultrasonic surgical instrument, and (iii) selecting the component from the list of components. ### Claim 36 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. ### Claim 37 (depends on 36) The system of claim 36, further comprising a machining device located at the clinical facility and communicatively coupled with the clinical facility system, wherein the machining device is configured to: (i) receive at least a portion of the set of modeling data, (ii) receive the component after fabrication by the additive manufacturing device and prior to use, and (iii) machine a contact portion of the component to a predetermined surface roughness based on the set of modeling data. ### Claim 38 (depends on 36) The system of claim 36, wherein the input is selected from the group consisting of: (i) a part number associated with the component; (ii) a part number associated with the ultrasonic surgical instrument; and (iii) an identifier received from a readable memory of the ultrasonic surgical instrument. ### Claim 39 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. ### Claim 40 (depends on 39) The clinical facility system of claim 39, wherein the processor is further configured to provide at least a portion of the set of modeling data to a machining device at the clinical facility, wherein the set of modeling data is usable by the machining device to machine a contact portion of the component to a predetermined surface roughness.