Surgical staplers are high-precision instruments integrated into robotic surgery systems to perform simultaneous tissue cutting and stapling. These tools are vital for minimally invasive procedures, facilitating efficient tissue transection, anastomosis, and resection with superior accuracy. Automating the stapling sequence reduces human error, enhances procedural safety, and improves patient outcomes through consistent staple line integrity and reduced operative time in complex surgeries.

Project Highlights:

• Explored three distinct pneumatic system architectures-
  • A rigid all-metal frame (combination of aluminum and steel) for maximum durability.
  • A hybrid metal-plastic model for balanced performance.
  • A full high-strength plastic version for specialized weight-critical applications.
• Through rigorous topology optimization and material replacement, achieved a 30% reduction in total device mass.
• This significant weight saving enhances portability and efficiency compared to the traditional all-metal baseline design.