MEDICAL DEVICE CONCEPT

Reimagining the look, feel, and function of a suture passing device

Client/Collaborators
Personal Project

Company/Partner(s)
Dr. William Barker, Orthopedic Surgeon at Orthopedic One

Approach
Competitive Research, Evaluative and Generative Research, Product Development

Methods/Tools
Ethnographic Research, One-on-One Interviews, Concept Sketching, Prototyping, Rhino CAD Development

OBJECTIVE

I used this project as an opportunity to combine two of my interests: design and orthopedic medicine. Partnering with an orthopedic surgeon, we set out to redesign the Arthrex Scorpion, an arthroscopic suture passing device for rotator cuff surgery.

OUTCOME

Research insights led to new possible design opportunities:

• The thumb press, instead of a full palm squeeze, was incorporated to minimize the likelihood that a surgeon would inadvertently execute the needle or clamp while pushing the instrument into the incision. The thumb press also allows for greater control at different angles and less overexerted force. Users are expected to press down to extend the needle up and push the suture threads up.

• Blue silicone pads were incorporated to provide additional comfort and grip, while also giving visual guidance as to where fingers should be placed on the device when in use.

• A curved handle and dual-side, T-shaped trigger for the clamp can be held vertically or horizontally, with the thumb press angled in 2 places for an easy reach. This was designed to improve comfort and grip, while also accommodating more universal hand sizes and positioning

• The trigger controls the open/close of the clamp. Sliding the trigger back to close the clamp also gives the surgeon a firmer grip while pushing the device into the arm.

• The blue part of the shaft (lower end) houses two small needles. It is a consumable plastic part that is pre-threaded for easy attachment and thrown away after each use. The intent behind this concept was to increase surgical efficiency (no need to thread) and reduce cost of the existing larger needle.

• The clamp is curved because newer models have proven that the curved shape fits better around the tendons in the arm.

PROCESS

Observations, Interviews, and Competitive Reviews

I interviewed surgeons , sometimes in the operating room while they were performing the procedure, and product reps. This allowed me to gain practical understanding of how the surgeon and surgical team interacted with the device (loading, using, cleaning, etc.). Interviews and observations, along with competitive research, surfaced pain points and areas of opportunity:

“Sometimes the tip of the needle will break off in a patient, especially if the surgeon squeezes to hard. Additionally, the scale and functionality (squeezing with your palm) makes it challenging for people (especially females) with smaller hands.” - Female Surgeon

“Working within a confined space is sometimes more difficult…hand and eye coordination are vital. You shouldn’t have to think about where your hand is located on the device, while you are using it.” - Dr. Barker

“While arthroscopic surgery is a cutting edge procedure, many of our surgeons are not using the Scorpion because of the high cost of disposable needles and lack of ease.” - Dr. Barker

“The new Scorpions will have 2 needles, instead of just the one.” - Arthrex Representative

Sketching and Prototyping

After sketching multiple concepts, I designed Plexiglass hand models. The models were constructed using a laser cutter, rubber bands, and springs to emulate the device’s various movements so Dr. Barker could hold and manipulate the models. Through these manipulations, Dr. Barker and I determined the T-shape grip and independent needle/clamp mechanisms could lead to better control and improved comfort.