Surgical cutting instrument forming method

A method of manufacturing a nonplanar, sheet metal tool from a planar metal blank of the type having two surfaces with a first surface opposing a second surface, the method comprising the steps of:

• applying to the first surface of the metal blank a predetermined design of etching resistant material defining exposed areas separated by resist areas;
• applying a layer of etching resistant material to the second surface of the metal blank which overlies at least the exposed areas on the first surface of the metal blank;
• shaping the metal blank into a nonplanar shape;
• placing the metal blank into a holder;
• providing a treatment applicator for applying an etchant and orienting the applicator so that the first surface faces the applicator;
• subjecting the exposed areas on the first surface of the metal blank to an etchant to form a surface with a cutting edge, the etchant being applied solely from the first surface of the metal blank and moving at least one of the holder and treatment applicator to evenly distribute the etchant onto the metal blank;
• and
• whereby the cutting edges so formed terminate in sharpened surfaces in the second surface and are protected by the layer of etching resistant material on the second surface of the metal blank.

A method of manufacturing a nonplanar, sheet metal tool from a planar metal blank of the type having two surfaces with a first surface opposing a second surface, the method comprising the steps of:

• applying to the first surface of the metal blank a predetermined design of etching resistant material defining exposed areas separated by resist areas;
• applying a layer of etching resistant material to the second surface of the metal blank which overlies at least the exposed areas on the first surface of the metal blank;
• shaping the metal blank into a nonplanar shape;
• placing the metal blank into a holder;
• providing a treatment applicator for applying an etchant and orienting the applicator so that the first surface faces the applicator;
• subjecting the exposed areas on the first surface of the metal blank to the etchant to form teeth having cutting edges, the etchant being applied solely from the first surface of the metal blank and moving at least one of the holder and treatment applicator to evenly distribute the etchant onto the metal blank;
• whereby the teeth so formed terminate in sharpened surfaces in the second surface and are protected by the layer of etching resistant material on the second surface of the metal blank;
• and
• bending at least selected teeth so formed to bring their respective cutting edges away from the second surface of the metal blank.

A method of manufacturing a nonplanar, sheet metal tool from a planar metal blank of the type having two surfaces with a first surface opposing a second surface, the method comprising the steps of:

• applying to the first surface of the metal blank a predetermined design of etching resistant material defining exposed areas separated by resist areas;
• applying a layer of etching resistant material to the second surface of the metal blank which overlies at least the exposed areas on the first surface of the metal blank;
• placing the metal blank into a holder;
• providing a treatment applicator for applying an etchant and orienting the applicator so that the first surface faces the applicator;
• subjecting the exposed areas on the first surface of the metal blank to the etchant to form teeth having cutting edges, the etchant being applied solely from the first surface of the metal blank and moving at least one of the holder and treatment applicator to evenly distribute the etchant onto the metal blank;
• whereby the teeth so formed terminate in sharpened surfaces in the second surface and are protected by the layer of etching resistant material on the second surface of the metal blank;
• shaping the metal blank into a nonplanar shape after subjecting the exposed areas to the etchant;
• and
• bending at least selected teeth so formed to bring their respective cutting edges away from the second surface of the metal blank.

A method of manufacturing a nonplanar, sheet metal tool from a planar metal blank of the type having two surfaces with a first surface opposing a second surface, the method comprising the steps of:

• applying to the first surface of the metal blank a predetermined design of etching resistant material defining exposed areas separated by resist areas;
• applying a layer of etching resistant material to the second surface of the metal blank which overlies at least the exposed areas on the first surface of the metal blank;
• shaping the metal blank into a nonplanar metal blank;
• placing the nonplanar metal blank into a holder;
• providing a treatment applicator for applying an etchant and orienting the applicator so that the first surface faces the applicator;
• subjecting the exposed areas on the first surface of the nonplanar metal blank to the etchant to form teeth having cutting edges, the etchant being applied solely from the first surface of the nonplanar metal blank and moving at least one of the holder and treatment applicator to evenly distribute the etchant onto the nonplanar metal blank;
• whereby the teeth so formed terminate in sharpened surfaces in the second surface and are protected by the layer of etching resistant material on the second surface of the nonplanar metal blank;
• and
• bending at least selected teeth so formed to bring their respective cutting edges away from the second surface of the nonplanar metal blank.

A method of manufacturing a nonplanar, sheet metal tool from a planar metal blank of the type having two surfaces with a first surface opposing a second surface, the method comprising the steps of:

• applying to the first surface of the metal blank a predetermined design of etching resistant material defining exposed areas separated by resist areas;
• applying a layer of etching resistant material to the second surface of the metal blank which overlies at least the exposed areas on the first surface of the metal blank;
• alternating the previously described resist design on the first and second surfaces so that alternating exposed areas on the first surface are overlaid by a layer of resist on the second surface and so that alternating exposed areas on the second surface are overlaid by a layer of resist on the first surface;
• shaping the metal blank into a nonplanar shape;
• placing the metal blank into a holder;
• providing a treatment applicator for applying an etchant and orienting the applicator so that the first surface faces the applicator;
• subjecting the exposed areas on the first surface of the metal blank to etchant to form teeth having cutting edges, the etchant being applied solely from the first surface of the curved metal blank and moving at least one of the holder and treatment applicator to evenly distribute the etchant onto the metal blank;
• whereby the cutting edges so formed terminate in sharpened surfaces in the second surface and are protected by the layer of etching resistant material on the second surface of the metal blank;
• removing the metal blank from the holder and replacing the metal blank into a holder so that the second surface faces the treatment applicator;
• subjecting the exposed areas on the second surface of the metal blank to etchant to form teeth having cutting edges, the etchant being applied solely from the second surface of the curved metal blank and moving at least one of the holder and treatment applicator to evenly distribute the etchant onto the metal blank;
• whereby the cutting edges so formed terminate in sharpened surfaces in the first surface and are protected by the layer of etching resistant material on the first surface of the metal blank;
• and
• bending at least selected teeth so formed along their respective bases to bring their respective cutting edges away from the surface of the metal blank.