System and method for making tapered looped suture

1. A method of forming a looped suture, the method comprising:

providing a system including an ultrasonic welder and an active anvil assembly;

receiving a first length of thread adjacent a second length of thread between the ultrasonic welder and the active anvil assembly;

moving at least one of an anvil member of the active anvil assembly or the ultrasonic welder towards the other of the ultrasonic welder or the anvil member until at least one of a predefined torque value is sensed by a sensor disposed in the active anvil assembly, a predefined force value is sensed by a sensor disposed in the active anvil assembly, or a predefined distance is sensed by a sensor disposed in the active anvil assembly;

activating the ultrasonic welder;

joining the adjacent first and second lengths of thread to form joined first and second lengths of thread; and

moving at least one of the anvil member or the ultrasonic welder away from the other of the ultrasonic welder or the anvil member.

2. A method of forming a looped suture, the method comprising:

providing a system including an ultrasonic welder, and an active anvil assembly that includes a first adjustable stage supporting the anvil member and a second adjustable stage supporting the first adjustable stage;

receiving a first length of thread adjacent a second length of thread between the ultrasonic welder and the active anvil assembly;

moving at least one of an anvil member of the active anvil assembly or the ultrasonic welder towards the other of the ultrasonic welder or the anvil member;

activating the ultrasonic welder;

joining the adjacent first and second lengths of thread to form joined first and second lengths of thread; and

moving at least one of the anvil member or the ultrasonic welder away from the other of the ultrasonic welder or the anvil member.

3. The method of claim 2 , wherein at least one of the anvil member or the ultrasonic welder is moved towards the other of the ultrasonic welder or the anvil until a predefined force value is sensed by a sensor disposed in the active anvil assembly.

4. The method of claim 2 , wherein at least one of the anvil member or the ultrasonic welder is moved towards the other of the ultrasonic welder or the anvil member until a predefined distance is sensed by a sensor disposed in the active anvil assembly.

5. The method of claim 1 , further comprising:

operably engaging the joined first and second lengths of thread with a trim gripper;

moving at least one of the trim gripper or a ultrasonic horn towards the other of the trim gripper or the ultrasonic horn;

removing excess thread from the joined first and second lengths of thread; and

moving the trim gripper away from the ultrasonic horn.

6. The method of claim 1 , wherein providing a system including an ultrasonic welder and an active anvil assembly includes providing an active anvil assembly that includes a first adjustable stage supporting the anvil member and a second adjustable stage supporting the first adjustable stage.

7. The method of claim 6 , wherein receiving a first length of thread adjacent a second length of thread between the ultrasonic welder and the active anvil assembly includes positioning the anvil member by translating at least one of the first adjustable stage or the second adjustable stage relative to the ultrasonic welder.

8. A method of forming a looped suture, the method comprising:

securing a first length of thread adjacent a second length of thread to form an overlapping length of thread;

engaging the overlapping length of thread with an anvil member of an active anvil assembly;

positioning the anvil member relative to an ultrasonic welder; activating the ultrasonic welder; and

activating a control assembly to move at least one of the anvil member or the ultrasonic welder towards the other.

9. The method of claim 8 , wherein the active anvil assembly includes a first adjustable stage supporting the anvil member and a second adjustable stage supporting the first adjustable stage and positioning the anvil member relative to the ultrasonic welder includes translating at least one of the first adjustable stage or the second adjustable stage relative to the ultrasonic welder.

10. The method of claim 9 , wherein translating at least one of the first adjustable stage or the second adjustable stage includes at least one of moving the first adjustable stage in a first or second direction or moving the second adjustable stage in a third or fourth direction.

11. The method of claim 8 , wherein moving at least one of the anvil member or the ultrasonic welder towards the other includes moving the anvil member relative to the ultrasonic welder until a sensor senses a predefined torque value.

12. The method of claim 11 , wherein moving at least one of the anvil member or the ultrasonic welder towards the other further includes moving the anvil member relative to the ultrasonic welder an additional user defined distance.

13. The method of claim 11 , further including determining the predefined torque value based on at least one of the size and type of thread being used.

14. The method of claim 8 , wherein moving at least one of the anvil member or the ultrasonic welder towards the other includes moving the anvil member relative to the ultrasonic welder until a force feedback provided by a sensor achieves a predefined set point.

15. The method of claim 14 , wherein moving at least one of the anvil member or the ultrasonic welder towards the other further includes moving the anvil member relative to the ultrasonic welder a user defined distance.

16. The method of claim 14 , further including determining the force feedback based on at least one of the size and type of thread being used.

17. The method of claim 2 , wherein at least one of the anvil member or the ultrasonic welder is moved towards the other of the ultrasonic welder or the anvil member until a predefined torque value is sensed by a sensor disposed in the active anvil assembly.