Precision Freehand Sculptor
Project Overview
Our Client is developing the Precision Freehand Sculptor (PFS), a new technology device to accurately cut bone during knee replacement surgery. This device tracks the position of the bur and bone such that the surgeon can not cut too deeply. When the bur reaches the desired depth of the implant the bur is retracted behind a guard on the tool, thus preventing over cutting.
The Challenge
Some project requirements were formidable, such as the high speed drive (65,000 RPM) and gear design, as well as fast reaction time of the bur retracting mechanisms, which operated in two directions. Other challenges included its small hand-held size, irrigation of the bur, the high precision components, the need for sterilization, and packaging its numerous motors and other components.
Our Solution
The client contacted us to develop concepts for the mechanical design of the tool itself, while they handled the software and electrical design internally. Of the options provided, a concept was chosen and developed into the current device. Some of the parts were manufactured in-house; all of the parts were inspected and the unit assembled in-house, then delivered to our client.
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Mechanical Design
Team
Month Turnaround
Amazing Result
The Latest Technology in Surgical Tools
High-Speed
Equipped with a high speed drive (65,000 RPM) and gear design.
Optimized for Performance
Fast reaction time of bur retracting mechanisms, which operate in two directions.
High Precision
Numerous motors and high precision components packaged in a small hand-held device.
Conceptual Development
During the concept development stage for this surgical tool, we produced solid models as well as part and assembly drawings. An engineering analysis with calculations was also performed to achieve the best results. After prototypes were approved, a fully operational unit was delivered to the client.
Finished Product
The conventional means for knee replacement surgery involved relatively basic cutting tools, such as burs and bone saws with manual jigs, to position the cut on the bone’s surface. Now, doctors can use our client’s Precision Freehand Sculptor to achieve better, faster results in surgery.