Dolphin Cut: Why the Edge of a Hernia Mesh Matters

When surgeons compare hernia meshes they usually look at material, weight, pore size and barrier. Less attention goes to the edges — yet every cut edge of a knitted mesh is in contact with tissue for as long as the mesh is implanted.

The problem with sharp edges

A knitted mesh is made of fine monofilaments. When it is cut, each severed filament leaves an end. Traditional cutting methods can leave those ends sharp or frayed, and sharp edges on a mesh implant can cause irritation, inflammation and even tissue damage — contributing to post-operative discomfort and longer recovery.

Laser cutting

Laser cutting improved matters by fusing filament ends as it cuts, and it became a common approach for finishing mesh. But laser cutting can leave microscopic irregularities at the fused edge.

Dolphin Cut Technology

Dolphin Cut is Futura Surgicare's proprietary edge-finishing process for hernia mesh. It does not rely on external energy sources such as lasers. According to Futura Surgicare, Dolphin Cut delivers:

• Perfectly smooth edges — unlike laser cutting, Dolphin Cut achieves smooth edges that minimise the risk of irritation and tissue damage.
• Patient comfort — designed to significantly reduce post-operative discomfort compared with meshes cut by laser or traditional methods.
• An enhanced safety profile — precise, consistent edges reduce the risk of complications such as infection and mesh migration.
• Consistent quality — a proprietary process that ensures consistent quality and reliability.
• Surgeon-centric design — easy handling and precise placement, helping to reduce surgical time.

The comparison above shows the difference between a normal cut, a laser cut and a Dolphin Cut edge.

Which meshes

Futura Surgicare introduced Dolphin Cut on its knitted polypropylene mesh, Knit — available in Ultra Soft, Soft, Macropore and Robust variants across 41 codes. Ask our team for the edge finish of a specific product and size.

Edges and handling

Smooth, sealed edges also matter to the surgeon: a mesh that does not fray is easier to trim, position and fix. Dolphin composite meshes are described in the same spirit — easily customisable, and trimmable without frayed or sharp edges.

This article is general information for healthcare professionals. Performance statements are from Futura Surgicare product literature; always refer to the Instructions for Use.