Low particulate surgical spear

A method of manufacturing a surgical sponge device comprising a sponge portion and a handle portion, the method including the steps of:

• i) providing a mould configured to define a plurality of voids that are connected to each other only along at least one edge portion of the mould;
• ii) filling the mould with reagents selected to generate an open cell foam material within the mould, the open cell foam material taking the form of a plurality of sponge portions having shapes defined by the plurality of voids, the sponge portions connected to each other only at base regions thereof corresponding to the void connections in the mould, the open cell foam material having an uncut external surface where it contacts the mould;
• iii) removing the open cell foam material from the mould;
• iv) washing and treating the open cell foam material;
• v) subsequent to step vi);
• connecting multiple handle portions to the open cell foam material at the base regions of the sponge portions and cutting the open cell foam material to separate the open cell foam material into a plurality of surgical sponge devices, each device having a handle portion connected to a sponge portion formed of the open cell foam material having the uncut external surface formed substantially all of its external surface except for at least one predetermined region of the external surface that is located close to the point of connection of the handle portion, the at least one predetermined region of the external surface being formed as a cut external surface, and wherein the handle portions each comprise a grip at one end thereof that mechanically grips mutually opposed external surface regions of the sponge portion an edge of the sponge portion.