DePuy Synthes
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CLIENT:
DePuy Synthes
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INDUSTRY:
Medical
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CAPABILITIES USED:
CNC Machining
Part Consolidation
Improved Functionality
Improved Manufacturability
Fathom Improvements Make An Orthopedic Tool More Reliable
Engineering experts from Fathom helped a medical manufacturing company improve the functionality and manufacturability of a surgical device used by orthopedic surgeons.
The Problem
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DePuy Synthes, a leading manufacturer of orthopedic devices, produces a reamer irrigator aspirator (RIA). It drills into the center of a femur bone to remove debris and create a channel in preparation for a marrow transplant or a metal rod implant.
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This tool consists of a steel drill head, which cuts and removes material from inside the femur, a flexible drive shaft that can conform to the shape of the marrow canal and a drill, which rotates the shaft and drill head.
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The interchangeable steel drill head enables surgeons to match the size of the cutting tool to the patient’s femur. The reusable drive shaft is made of nitinol, a flexible nickel-titanium alloy.
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For its second-generation RIA, the manufacturer sought to improve the flow of aspirated tissue and bone debris. Also, the disposable cutting head needed to be redesigned so it would attach more reliably to the shaft and wouldn’t come loose during surgery.
The Solution
Fathom experts worked with the manufacturer’s engineers to address their functionality improvements but also recommended design changes that would improve manufacturability, reduce the number of parts and help reduce the cost of the second-generation RIA. As part of its efforts to improve the tool’s reliability, Fathom engineers identified a concern with the existing pin system used to secure the drill head tangs to the drive shaft. Instead of press-fitting the pins in place, Fathom suggested welding them and modifying their locations to better grip the drill and improve the tool’s durability.
The Results
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Increased Device Durability // By switching to laser welding, the drill head has a tighter snap-fit to keep it securely attached during surgery.
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Simpler Operation for Surgeons // The RIA removes tissue more thoroughly, so doctors have greater confidence in using it.
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Optimized Manufacturability // Fewer parts and more durable weld points help keep manufacturing costs under control.
