Methods for manufacturing endodontic instruments by milling

1. A method of manufacturing an endodontic instrument for use in performing an endodontic procedure, comprising:

(a) providing a metallic thread or wire having a longitudinal axis; and

(b) advancing the metallic thread or wire along the longitudinal axis at a feedrate while contacting at least a portion of the metallic thread or wire with a plurality of rotating shank-type endmilling tools that are peripherally spaced about the longitudinal axis of the thread or wire so as to remove a portion of material from the thread or wire.

2. A method as recited in claim 1 , wherein (b) yields a metallic rod including a cutting portion having a plurality of cutting edges.

3. A method as recited in claim 1 , further comprising rotating the metallic thread or wire about the longitudinal axis simultaneous with (b).

4. A method as recited in claim 3 , wherein the plurality of endmilling tools simultaneously contacts at least a portion of the metallic thread or wire so as to simultaneously form a plurality of helical flutes within the metallic thread or wire.

5. A method as recited in claim 1 , wherein the metallic thread or wire is initially cylindrical in shape.

6. A method as recited in claim 5 , wherein at least a portion of the initially cylindrical metallic thread or wire is shaped by the plurality of endmilling tools so as to yield an intermediate metallic rod having a polygonal cross section.

7. A method as recited in claim 6 , wherein the polygonal cross section is at least one of a square, a triangle, a polygon having straight surfaces, a polygon having concave surfaces, or a polygon having convex surfaces.

8. A method as recited in claim 6 , further comprising torsioning the intermediate metallic rod having a polygonal cross section so as to form helical cutting edges in a cutting portion of the instrument.

9. A method as recited in claim 1 , wherein (b) produces a cutting portion that is tapered.

10. A method as recited in claim 9 , wherein the taper is between about 0.02 mm/mm and about 0.06 mm/mm.

11. A method as recited in claim 1 , wherein the plurality of endmilling tools are located in a single plane.

12. A method as recited in claim 1 , wherein at least one of the endmilling tools is located in a plane different from at least one other endmilling tool.

13. A method as recited in claim 1 , wherein at least one of the endmilling tools comprises a rounded ball head end.

14. A method as recited in claim 1 , wherein at least one of the endmilling tools comprises a substantially flat head end.

15. A method as recited in claim 1 , wherein the metallic thread or wire is contacted and milled by an end of at least one of the endmilling tools.

16. A method as recited in claim 1 , wherein the metallic thread or wire is contacted and milled by a side of at least one of the endmilling tools.

17. A method as recited in claim 1 , further comprising cold forming the metallic thread or wire to yield a metallic rod including a cutting portion having a plurality of cutting edges.

18. A method of manufacturing an endodontic instrument for use in performing an endodontic procedure, comprising:

(a) providing a metallic thread or wire having a longitudinal axis;

(b) advancing the metallic thread or wire along the longitudinal axis at a feedrate while contacting at least a portion of the metallic thread or wire with a plurality of rotating shank-type endmilling tools so as to remove a portion of material from the metallic thread or wire; and

(c) rotating the metallic thread or wire about the longitudinal axis simultaneous with (b) so as to form a plurality of helical flutes within the metallic thread or wire.

19. A method as recited in claim 18 , wherein (b) includes contacting at least a portion of the metallic thread or wire with at least three rotating shank-type endmilling tools so as to form at least three helical flutes in (c).

20. A method of manufacturing an endodontic instrument for use in performing an endodontic procedure, comprising:

(a) providing a metallic thread or wire having a longitudinal axis;

(b) advancing the metallic thread or wire along the longitudinal axis at a feedrate while contacting at least a portion of the metallic thread or wire with a plurality of rotating shank-type endmilling tools that are peripherally spaced about the longitudinal axis so as to remove a portion of material from the wire, wherein at least a portion of the metallic thread or wire is shaped by the plurality of rotating shank-type milling tools so as to yield an intermediate metallic rod having a polygonal cross section; and

(c) torsioning the intermediate metallic rod having a polygonal cross section so as to form helical cutting edges in a cutting portion of the instrument.

21. A method as recited in claim 20 , wherein the polygonal cross section is at least one of a square, a triangle, a polygon having straight surfaces, a polygon having concave surfaces, or a polygon having convex surfaces.