Embedded Files
In order to encompass all components of successful development of an endoscopic tissue stapler, from specialized staple manufacturing to staple deployment to staple removal, the following components were designed for this project:
Endoscopic Stapler
Endoscopic Stapler
Exploded view of the stapler, in its short shaft configuration, with components labeled. Click on each component below to see more details about their design.
Close-up view of the stapler head with a staple loaded before (top) and after (bottom) trigger actuation.
Handle & Trigger
The handle and trigger of the stapler are designed to be comfortable to hold and actuate while simultaneously delivering enough torque to the anterior end to bend the staples to their final desired shape.
Based upon the handle design of a common surgical tool known as a Kerrison Rongeur, used for cutting bone in hard to reach areas, the stapler handle delivers excess force while being easy and comfortable to use.
Shaft & Arm
The shaft of the stapler consists of an elongated enclosed body, with a 5 degree upwards bend at the anterior end to allow for line of sight to the stapler tip during use.
The arm of the stapler slides through the hollow shaft and interacts with the staples at the stapler head.
The shaft is easily customizable to any desired length.
Head
At the head of the stapler, the pronged end of the arm pushes the loaded staple around the extended end of the shaft, as seen in the right image above.
The notched shape of the prongs prevents unwanted rotation in the staple during the application process.
The distance between the prongs in combination with the width of the extended shaft end determines the final staple shape and can be easily adjusted.
Staple Die
Staple Die
3D-printed staple die accompanied by 6 staples stamped from it.
A 3D-printed staple die was used to precisely manufacture steel staples from 28 gauge steel wire for use during the testing process of the endoscopic stapler.
This die effectively eliminated large variations between staples and drastically increased the efficiency of testing during the design process.
After the staple shape had been stamped using the die, wire cutters were used to give the puncturing ends of the staples a sharp point.
Staple Cartridge
Staple Cartridge
Since the endoscopic stapler holds and deploys a single staple at a time, an external staple cartridge was created.
This cartridge drastically reduces the time needed to reload the stapler during a procedure while simultaneously removing the need to touch staples in order to load them, making the overall process both faster and more sanitary.
This cartridge is modular and can easily be expanded to hold any necessary number of staples.
3D-printed staple cartridge loaded with three stamped staples.
Staple Remover
Staple Remover
CAD and 3D-printed depictions of the staple removal tool before (left) and after (right) trigger actuation.
The removal tool utilizes the same overall design as the stapler, with a different tip design which bends the staples from a closed initial position to an open final position.
After removal, the staple is gripped tightly between the two pieces until the tool has been removed from the throat and the trigger is released.
Complete Chicken Breast Testing
Complete Chicken Breast Testing
3xStapleFinal.movTesting cartridge reloading efficiency
StapleRemoveFinal.movTesting staple remover effectiveness
Additional models, photos, and videos of these components are located on the Multimedia Page.
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