Instruments for ACDF Surgery
Sponsor: Medtronic
Role: Industrial Designer
8 Person Team (Mechanical, Chemical, Material Engineers)
We addressed two key shortcomings in existing designs: a screwdriver that ensures secure screw retention while maintaining axial alignment and the lack of a reliable method for gripping the plate during operation.
Background
ACDF surgery relieves spinal pressure for patients with cervical spine compression by removing a damaged disc, replacing it with a bone graft, and securing it with a metal plate.
What’s Wrong with Current Tools?
At first glance, they seemed fine—until we spoke to surgeons. The tools were so inadequate that they relied on their fingers and tweezers instead, increasing surgery time and infection risk.
ScrewdriversFail to hold screws securely, risking them falling mid-operation, or grip them too tightly, making removal difficult and aggressive.
Plate Holders Often too large to fit in the operation incision and positioned at the wrong angle, making plate holders difficult to pick up.
Understanding Procedures.
Conversations with Surgeons.
Hands-On Tool Use.
Initial Exploration
Exploring various interactions, mechanisms, and form
Concept Development
A metal sleeve and a stretchy rubber gasket at the tip. The gasket securely holds the screw, and retracting it releases the screw.
A split tip that expands for screw retention and contracts for screw release. The mechanism narrows the bit, reducing its diameter to match the screw’s head.
A flexible neck for precise placement, a detachable drill guide for visibility, and adjustable grip for secure handling.
A narrower profile drill guide with a spring-loaded adjustable grip that expands inside the body.
Storyboard
Visualizing a streamlined workflow with redesigned tools.