Manufacturing an articulating ophthalmic surgical probe

Abstract

A method of manufacturing an articulating ophthalmic surgical probe includes providing a cannula having an outer diameter of 20 Ga or less and a slotted tip, permanently attaching a pull wire to the slotted tip, permanently attaching a metal anchor to a distal end of the pull wire, positioning a weld pin within a handle assembly that is sized to fit within a single hand, and welding the metal anchor to the weld pin within the handle assembly.

1 . An articulating ophthalmic surgical probe, comprising:
 a handle formed from a rigid plastic material and sized to fit in a single hand;   a rigid cannula extending from the handle having a diameter of 20 Ga or less;   a slotted tip at a distal end of the cannula;   at least one optical fiber extending through the handle, the single rigid cannula, and the slotted tip;   a pull-wire permanently attached to the slotted tip at a distal end of the pull-wire, wherein when the pull-wire exerts tension on the slotted tip, the slotted tip will deviate from straight to a bend angle controlled by the tension in the pull-wire, the slotted tip formed from a resilient material that will restore to the straight position when the tension exerted by the pull-wire is released;   an anchor permanently attached to a proximal end of the pull wire; and   a proximal weld pin secured within the handle welded to the anchor.   
     
     
         2 . The probe of  claim 1 , further comprising:
 a key feature permanently attached to the rigid cannula; and   a keypath pocket holding the key feature to align the slotted tip rotationally with the handle.   
     
     
         3 . The probe of  claim 1 , wherein:
 the rigid cannula has a flared proximal end;   the handle further comprises a guide pin spaced from the flared proximal end of the rigid cannula contacting the at least one optical fiber, wherein the guide pin holds the at least one optical fiber away from an outer edge of the flared proximal end.   
     
     
         4 . The probe of  claim 1 , wherein:
 the probe further comprises a distal weld pin welded to the cannula.   
     
     
         5 . The probe of  claim 1 , wherein:
 the anchor is a cylindrical anchor having an outer diameter; and   the proximal weld pin has a U-groove having an internal diameter larger than the outer diameter of the anchor so that the anchor fits within a bottom of the U-groove.   
     
     
         6 . The probe of  claim 4 , wherein the proximal weld pin and the distal weld pin are formed in an integral assembly. 
     
     
         7 . The probe of  claim 1 , wherein the rigid plastic material is acrylonitrile butadiene styrene (ABS), acetal homopolymer, or polypropylene. 
     
     
         8 . The probe of  claim 1 , wherein the cannula is formed of stainless steel. 
     
     
         9 . The probe of  claim 1 , wherein the pull wire is formed of stainless steel. 
     
     
         10 . The probe of  claim 1 , wherein the weld pin is formed of stainless steel. 
     
     
         11 . A method of manufacturing an articulating ophthalmic surgical probe, comprising:
 providing a cannula having an outer diameter of 20 Ga or less and a slotted tip;   permanently attaching a pull wire to the slotted tip;   permanently attaching a metal anchor to a proximal end of the pull wire;   positioning a proximal weld pin within a handle assembly, the handle assembly sized to fit within a single hand; and   welding the metal anchor to the proximal weld pin within the handle assembly.   
     
     
         12 . The method of  claim 11 , wherein:
 the handle assembly further comprises a keypath pocket at a distal end of the handle assembly; and   the method further comprises:
 permanently attaching a key feature to the cannula; and 
 threading the pull wire through the distal end of the handle assembly until the key feature fits with the keypath pocket to rotationally align the slotted tip relative to the handle assembly. 
   
     
     
         13 . The method of  claim 11 , wherein:
 the method further comprises:
 positioning a distal weld pin within the handle assembly; and 
 welding the cannula to the distal weld pin within the handle assembly. 
   
     
     
         14 . The method of  claim 11 , wherein the step of welding the metal anchor is performed using laser welding. 
     
     
         15 . The method of  claim 11 , further comprising:
 snap fitting a thumb switch having a compressible insert into a slot within the handle assembly, the slot having a widened portion corresponding to a position of the compressible insert when the thumb switch is in a rearmost position; and   placing the thumb switch in the rearmost position to allow the compressible insert to expand into the widened portion of the slot, thereby retaining the thumb switch in the rearmost position.