Anvil for Circular Surgical Stapler and Associated Method of Manufacture with MIM

A method of manufacturing an anvil of a surgical circular stapler, wherein the anvil includes a head and a shank extending proximally from the head, wherein the head includes an annular array of staple forming pockets, the method comprising:

• (a) forming the head including the annular array of staple forming pockets;
• (b) coining or electrochemical machining at least a portion of at least one staple forming pocket of the annular array of staple forming pockets;
• (c) machining the shank;
• and
• (d) coupling the head with the shank that were separately manufactured.

A surgical instrument comprising:

• (a) a body;
• (b) a shaft extending distally from the body;
• (c) a stapling head assembly positioned at a distal end of the shaft, wherein the stapling head assembly includes:
• (i) an anvil coupling feature,
• (ii) at least one annular array of staples, and
• (iii) a staple driver, wherein the staple driver is operable to drive the at least one annular array of staples;
• and
• (d) an anvil, wherein the anvil is configured to couple with the anvil coupling feature, wherein the anvil is further configured to deform the staples driven by the staple driver, wherein the anvil comprises:
• (i) a shank, and
• (ii) a head configured to be coupled with the shank, wherein the head includes an annular array of staple forming pockets, wherein a portion of at least one staple forming pocket of the annular array of staple forming pockets has a smoother and denser surface than the remainder of the staple forming pocket.