High velocity forming of medical device casings

A method of creating casing sections of medical devices, comprising:

• providing an enclosure having a first area where a die is present, the die having a surface with a first contour;
• affixing a first object having a first object contour to the surface of the die at a desired location so that the first object contour and the first contour are combined to provide a second contour;
• placing a first workpiece within the enclosure adjacent the die;
• at least partially filling the enclosure with a liquid;
• and
• creating a first spark within the liquid to produce a pressure wave that forces the first workpiece into the die and causes the first workpiece to achieve the second contour.

A device for creating casing sections of medical devices, comprising:

• an enclosure;
• a pair of electrodes within the enclosure and defining a spark gap;
• a die having a first contour;
• and
• a first object affixed to the die, the first object having a first object contour, the first object contour and the first contour forming a second contour.

A method of creating casing sections of medical devices, comprising:

• providing an enclosure having a first area where a die is present, the die having a surface with a first contour, the die further having a contour edge and having an extendable cutting blade around the contour edge;
• placing a first workpiece within the enclosure adjacent the die;
• at least partially filling the enclosure with a liquid;
• while the extendable cutting blade is in a retracted state, creating a first spark within the liquid to produce a pressure wave that forces the first workpiece into the die and causes the first workpiece to achieve the first contour;
• after creating the first spark, extending the cutting blade to an extended state;
• and
• while the extendable cutting blade is in the extended state, creating a second spark within the liquid to produce a pressure wave that forces the first workpiece into the cutting blade to trim the workpiece along the contour edge.

A device for creating casing sections of medical devices, comprising:

• an enclosure;
• a pair of electrodes within the enclosure and defining a spark gap;
• a die within the enclosure and having a first contour and a contour edge;
• and
• a cutting blade that extends and retracts about the contour edge.

A method of creating casing sections of medical devices, comprising:

• providing an enclosure having a first area where a die is present, the die having a surface with a first contour corresponding to a desired contour of a casing section;
• placing a first workpiece comprising flat sheet stock within the enclosure adjacent the die;
• at least partially filling the enclosure with a liquid;
• and
• creating a first spark within the liquid to produce a pressure wave that forces the flat sheet stock of the first workpiece sheet into the die and causes the flat sheet stock of the first workpiece sheet to achieve the first contour;
• and
• mating the first workpiece having the first contour with a second workpiece while including electronic circuitry that performs medical tasks within a space present between the first workpiece and the second workpiece once mated.

A method of creating casing sections of medical devices, comprising:

• providing an enclosure having a first area where a die is present, the die having a surface with a first contour;
• placing a first workpiece within the enclosure adjacent the die;
• at least partially filling the enclosure with a liquid;
• creating a first spark within the liquid to produce a pressure wave that forces the first workpiece into the die and causes the first workpiece to achieve the first contour;
• and
• diffusing the pressure wave as it travels to the first workpiece;
• and
• mating the first workpiece having the first contour with a second workpiece while including electronic circuitry that performs medical tasks within a space present between the first workpiece and the second workpiece once mated.

A device for creating casing sections of medical devices, comprising:

• an enclosure containing a liquid;
• a pair of electrodes within the enclosure and defining a spark gap within the liquid;
• a die within the liquid and having a first contour;
• and
• a pressure wave diffuser within the liquid and between the spark gap and the die, the pressure wave diffuser comprising a plurality of individual channels.