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Production and Application of Artificial Diamand Blades utilizing Microsystem Technology
Spraul C. W.,
Universität Ulm, Augenklinik und Poliklinik (Ulm)
Purpose: In ophthalmic microsurgery the quality of the knifes may be of utmost importance for the quality of the surgery itself. Besides metal blades diamond knives are also used in ophthalmic surgery. However, they are still very expensive and the shape of the blades as well as their cutting performance are limited due to the mechanical polishing process. The purpose of this study was to investigate a novel production method transferred from microsystems technology to diamond blade manufacture.
Methods: The fabrication method is based on so-called highly oriented, polycrystalline diamond (HOD) films grown on silicon using a microwave assisted plasma process. This results in a very low surface roughness and allows the use of these diamond films for the production of high quality, high precision cutting tools without post-deposition polishing. The mechanical properties of the synthetic diamond films are almost equal to those of natural diamond. The cutting surface produced with these knifes were investigated using electron microscopy.
Results: Improved cutting performance results from polishing by gas atoms in a plasma process instead of using diamond powder for the mechanical polishing process of conventional blades. This allows an almost force free tissue cutting with a very smooth cutting surface. Additionally, the fabrication methods transferred from semiconductor manufacturing allow highly reproducible batch production and the integration of electronic devices.
Conclusions: For the first time, the new process offers surgeons the possibility to design blades with a geometry close to their personal needs. The implementation of electronic devices to realize an intelligent blade is possible and may lead to improvements in actual or even the development of new surgical techniques.