Methods of forming medical reamers

1. A method of forming a cutting tool comprising:

forming a plurality of panels from one or more flat sheets of metal, the plurality of panels including a plurality of side panels and a dome member extending along a radial axis of the cutting tool;

stamping the plurality of panels to form a plurality of cavities and punching holes at or adjacent to the plurality of cavities to provide a plurality of bone-chip-receiving openings and a plurality of cutting edges; and

coupling the plurality of stamped panels to a frame member to form the cutting tool,

wherein the frame member is formed with an elongated center member having a length extended along a longitudinal axis of the cutting tool fixed at one end to a base member extended along the radial axis and the act of coupling the plurality of stamped panels to the frame member comprises:

securing the plurality of stamped side panels to the frame member so that the plurality of stamped side panels at least partially surround the elongated center member of the frame member along a portion of the length of the elongated center member, and

securing the stamped dome member to the frame member so that the stamped dome member extends over an end of the elongated center member opposite the end fixed to the base member.

2. The method of claim 1 , wherein the act of forming the plurality of cavities comprises forming a plurality of V-shaped cavities.

3. The method of claim 2 , wherein the act of forming the plurality of panels further comprises stamping the one or more panels to create a desired height of the cutting edges and to provide a desired curvature of the one or more panels.

4. The method of claim 3 , wherein the act of stamping the one or more panels to create a desired height of the cutting edges and to provide a desired curvature of the one or more panels is performed in a single stamping operation.

5. The method of claim 1 , wherein the act of forming a plurality of side panels from one or more flat sheets of metal comprises forming the plurality of cutting edges with different zones that have cutting edges with different characteristics, the different zones comprising a polar zone, a transition zone, and an equatorial zone.

6. The method of claim 5 , wherein respective cutting edges each define a cutting angle between the cutting edge and a perpendicular surface to a first side of the cutting tool, and the cutting angle between cutting edges in the polar zone are larger than those defined by cutting edges in the transition zone, and the cutting angle between cutting edges in the transition zone are larger than those defined by cutting edges in the equatorial zone.

7. The method of claim 1 , wherein respective panels have cutting edges with orientation angles that vary along the respective panel.

8. The method of claim 1 , wherein the act of securing the plurality of stamped panels to the frame member comprises laser welding.

9. The method of claim 1 , wherein the act of coupling the plurality of stamped panels to the frame member comprises: placing the plurality of stamped panels into an injection molding tool; and injection molding the frame member around the plurality of stamped panels to create the frame member.

10. The method of claim 1 , wherein the one or more flat sheets of metal have a thickness less than 0.040 inches.

11. The method of claim 1 , wherein the act of punching holes at or adjacent to the plurality of cavity comprises forming bone-chip-receiving openings with a funnel angle that is between 20 and 40 degrees.

12. The method of claim 1 , wherein the cutting tool comprises a hollow spherical reamer, a hollow tapered reamer, or a hollow cylindrical reamer.

13. The method of claim 1 , further comprising:

determining an effective functional life of the cutting tool.

14. The method of claim 1 , wherein, when coupled to the frame member, the plurality of stamped panels define a plurality of latitude lines about the axis of rotation of the cutting tool and the plurality of formed cutting edges have orientation angles relative to the latitude lines that vary.