In surgical stapler anvils and end effectors, edge definition and feature geometry directly influence staple formation, cutting performance, and tissue interaction. Inconsistent edge profiles or minor burr formation can affect alignment, compression behavior, or staple leg formation during actuation. Conventional machining methods rely on physical tool contact, which can introduce localized deformation in thin sections or require secondary deburring processes that add variability to tightly controlled assemblies.
 

PECM removes material through controlled electrochemical dissolution rather than mechanical shear. Because the cathode does not contact the workpiece, fine features and transition edges can be formed with reduced risk of distortion. This is particularly valuable in components with tight mating interfaces, precision slots, or repeated geometric patterns that must function consistently across cycles.
 

In surgical robotics, internal motion systems such as strain wave gears demand accurate tooth profiles and repeatable geometry to maintain torque transmission accuracy and minimize backlash. Small geometric deviations in gear profiles can accumulate into measurable positioning error at the instrument tip. PECM supports controlled feature generation in conductive gear materials, enabling consistent replication of intricate profiles while minimizing mechanically induced stress at the cut interface.
 

Across both handheld and robotic surgical systems, production scalability is critical. Feature-to-feature consistency within a component ensures predictable device behavior, while part-to-part repeatability across manufacturing lots supports validation and long-term reliability. Through custom cathode design and controlled pulsed electrochemistry, Voxel provides a repeatable manufacturing pathway for surgical components where precision mechanics and regulated production requirements must coexist.