Anvil for circular surgical stapler and associated method of manufacture with MIM

1. A method of manufacturing an anvil of a surgical circular stapler, wherein the anvil includes a head and a shank extending proximally from the head, the method comprising:

(a) forming the head of the anvil of the surgical circular stapler using a metal injection molding process from a feedstock that comprises finely-powdered metal and a binder material;

(b) forming an annular array of staple forming pockets in the head of the anvil;

(c) machining the shank of the anvil;

(d) inserting the shank of the anvil through a central aperture of the head of the anvil; and

(e) coupling together the head and the shank of the anvil of the surgical circular stapler by overmolding a cap onto the head of the anvil to capture a flange of the shank between the cap and the head.

2. The method of claim 1 , further comprising:

forming the shank using a metal injection molding process prior to machining the shank.

3. The method of claim 1 , further comprising:

machining at least a portion of the head after forming the head using the metal injection molding process.

4. The method of claim 1 , wherein forming the head using the metal injection molding process and forming the annular array of staple forming pockets in the head are performed simultaneously.

5. The method of claim 1 , wherein forming the head using the metal injection molding process occurs before forming the annular array of staple forming pockets in the head.

6. The method of claim 1 , wherein after forming the annular array of staple forming pockets using the metal injection molding process, the method further comprises coining or electrochemical machining at least a portion of at least one staple forming pocket of the annular array of staple forming pockets.

7. The method of claim 6 , wherein the portion coined or electrochemically machined is both smoother and denser than the remainder of the staple forming pocket that was not coined or electrochemically machined.

8. The method of claim 1 , wherein the shank includes a flange extending radially outward from a distal end of the shank, wherein inserting the shank through the central aperture of the head further comprises inserting the shank through the central aperture of the head until the flange contacts the head.

9. The method of claim 8 , wherein forming the head further comprises forming the head to include a distal outer surface and a distal recessed portion that is disposed proximal to the distal outer surface, wherein inserting the shank through the central aperture of the head until the flange contacts the head further comprises inserting the shank through the central aperture of the head until the distal recessed portion contacts the flange of the shank.

10. The method of claim 8 , wherein the flange includes an inner shallow portion and a rounded outer edge portion, wherein coupling the head with the shank further comprises coupling a proximal surface of the flange with a distal surface of the head.

11. The method of claim 1 , wherein the cap includes at least one proximally facing projection and the head includes at least one corresponding recess, wherein coupling the cap with the head further comprises inserting the at least one proximally facing projection into the at least one recess.

12. A method of manufacturing an anvil of a surgical circular stapler, wherein the anvil includes a head and a shank extending proximally from the head, wherein the head includes an annular array of staple forming pockets, the method comprising:

(a) forming the head of the anvil including the annular array of staple forming pockets;

(b) coining or electrochemical machining only a predetermined portion of at least one staple forming pocket of the annular array of staple forming pockets to have a smoother and denser surface than a remainder of the staple forming pocket that is less dense than the predetermined portion;

(c) machining the shank of the anvil while the shank is separate from the head of the anvil;

(d) inserting the shank of the anvil through a central aperture of the head of the anvil; and

(e) coupling together the head with the shank.

13. The method of claim 12 , wherein the predetermined portion coined or electrochemically machined is a central portion of the at least one staple forming pocket, wherein the central portion, once coined or electrochemically machined, is both smoother and denser than another portion that was not coined or electrochemical machined.

14. The method of claim 12 , further comprising:

forming the shank using a metal injection molding process prior to machining the shank.

15. A surgical instrument comprising:

(a) a body;

(b) a shaft extending distally from the body;

(c) a stapling head assembly positioned at a distal end of the shaft, wherein the stapling head assembly includes:

(i) an anvil coupling feature,

(ii) at least one annular array of staples, and

(iii) a staple driver, wherein the staple driver is operable to drive the at least one annular array of staples; and

(d) an anvil, wherein the anvil is configured to couple with the anvil coupling feature, wherein the anvil is further configured to deform the staples driven by the staple driver, wherein the anvil comprises:

(i) a shank, and

(ii) a head configured to be coupled with the shank, wherein the head includes an annular array of staple forming pockets, wherein only a predetermined portion of at least one staple forming pocket of the annular array of staple forming pockets has a smoother and denser surface than the remainder of the staple forming pocket that is less dense than the predetermined portion.

16. The surgical instrument of claim 15 , wherein the predetermined portion is a central portion that is interposed between first and second outer portions, wherein the first and second outer portions have a less dense surface than the central portion of the staple forming pocket.

17. The method of claim 1 , wherein the shank includes laterally extending body, wherein the laterally extending body includes a bore configured to receive a trocar, wherein the shank, including the laterally extending body, is integrally formed together as a unitary piece.

18. The method of claim 12 , wherein coupling together the head and the shank further comprises overmolding a cap onto the anvil to capture a flange of the shank between the cap and the head.

19. The method of claim 12 , wherein coupling together the head and the shank further comprises overmolding a cap onto the head of the anvil using one or more overmolding processes.