Method for producing a deflectable insertion tool

1. A method of producing a bendable tip for an instrument, comprising:

mounting a tube for an instrument in a CNC controlled rotational and axially movable holder of a laser cutting machine, with a distal end of the tube extending from the holder;

activating a laser cutter;

laser cutting wedge shaped partial circumferential openings in the tube to define a plurality of radially extending ribs at the distal end of the tube, the ribs being connected together by an axially extending spine, and the ribs having first and second axial sides;

during the laser cutting, forming in each of the ribs in at least one of the first or second axial sides, at least one of an axial projection or a recess, and forming in a facing one of the at least one of the first or second axial sides of an adjacent one of the ribs at least one of a corresponding complementary mating recess or a corresponding axial projection, wherein the at least one of the axial projection and the corresponding complementary mating recess or the recess and the corresponding axial projection formed in each of the ribs are arranged in first, second and third axially extending rows spaced from the spine, wherein the recesses and corresponding complementary mating recesses of the first and third rows have a curved path extending from the first and second axial sides toward the spine and the axial projections and corresponding axial projections of the first and third rows having a complementary curved shape to the curved path of the respective recesses and corresponding complementary mating recesses, the recesses and corresponding complementary mating recesses of the second row extending along a straight axial path and the respective axial projections and corresponding axial projections having a complementary shape.

2. The method of claim 1 , further comprising:

connecting at least one tension wire to the distal tip; and

extending the at least one tension wire through the tube to a tip control actuator located at a proximal end of the tube.

3. The method of claim 1 , further comprising:

creating a clearance in a circumferential direction of about 0.1-0.4 mm between the axial projections and the complementary mating recesses and/or the recesses and the corresponding axial projections.

4. The method of claim 1 , further comprising:

forming the tube from a shape memory alloy.

5. The method of claim 4 , wherein the shape memory alloy is Nitinol.

6. The method of claim 1 , further comprising:

after the laser cutting, at least one of electropolishing or abrasive cleaning of the tube.

7. The method of claim 1 , further comprising:

during the laser cutting, forming a tension wire connection opening at the distal end of the tube circumferentially opposite to the spine.

8. The method of claim 1 , further comprising:

during the laser cutting, forming rounded openings at corners of the wedge shaped partial circumferential openings adjacent to the spine.

9. The method of claim 8 , wherein the rounded openings are oval having a major axis extending in the axial direction of the tube.

10. The method according to claim 1 , wherein the tube is a part of a length of tube stock, and the method further comprising:

mounting the tube stock in the CNC controlled rotational and axially movable holder, and after the laser cutting, advancing the tube stock through the moveable holder until a sufficient length is exposed to form a desired length for the tube, and

cutting the tube from an end of the tube stock.

11. The method according to claim 1 , wherein the laser cutting further comprises laser cutting the wedge shaped partial circumferential openings with different shapes to provide a variable bend profile.

12. The method according to claim 1 , wherein the tube is an end tube, and the method further comprising assembling the end tube with a guide tube.

13. The method according to claim 1 , further comprising assembling a tip control actuator to the tube.