Reliable instruments for precise procedures
Surgical procedures require absolute precision. A surgeon must be able to perform every movement perfectly. An unreliable instrument can have fatal consequences. Nevertheless, there are always problems in practice. Instruments that do not fit perfectly in the hand, whose blades become blunt too quickly or whose ergonomics are not adapted to the requirements of long procedures.
Manufacturers of surgical instruments are faced with the task of developing products that not only fulfil medical and regulatory standards, but also meet the highest demands of users. This is where we come in with comprehensive functional analysis, innovative simulation technology and a development process that is optimised down to the smallest detail.
Many companies develop surgical instruments primarily according to functional requirements. Ergonomics, material selection and durability are often only focussed on later. This results in products that do not perform optimally on the market. We take a different approach. From the outset, we consider all relevant factors as a whole.
Our instruments are designed to fit seamlessly into a surgeon’s workflow. We analyse gripping and cutting movements and develop designs that are intuitive to use and reduce fatigue. The shape is designed so that the instrument sits comfortably in the hand even during long operations and does not cause unnecessary strain.
The choice of material determines quality and durability. We rely on biocompatible, durable materials that can withstand sterilisation processes. Each material is tested for its mechanical properties to ensure consistently high performance.
We use kinematic simulations to analyse mechanical loads and wear processes as early as the development phase. We recognise weak points before a physical prototype is created. This enables us to make targeted adjustments that extend the service life of the instruments and ensure optimum function.
Every surgical instrument must fulfil regulatory requirements. We incorporate MDR, ISO standards and FDA regulations into the development process right from the start. Documentation, validation and quality assurance are an integral part of our process. This reduces risks in the approval process and enables a rapid market launch.
A practical example The surgical scissors that didn’t cut
A medical technology company approached us with an acute problem. Surgical scissors that were already established on the market quickly lost their sharpness. Operations were becoming more difficult, the service life was inadequate and complaints were increasing.
Our team analysed the problem and optimised the scissors in several steps. Firstly, we analysed the material structure, cutting kinematics and manufacturing processes. We discovered that the cutting geometry was not optimised for the material used. Using simulations, we were able to precisely determine the optimum cutting angle and force distribution. This enabled us to develop a design that reduces cutting resistance and maintains the sharpness of the blade for longer.
The next step was to optimise the material. We opted for high-strength ceramic cutting edges in combination with a special bonding technique to significantly extend the service life. The new bond ensured a more stable fixation of the blades and reduced material fatigue.
At the same time, we adapted the production processes. High-precision manufacturing technologies and optimised supply chains ensured that the new scissors could be produced with consistent quality.
The result was that the optimised scissors lasted more than twice as long as the previous model. Surgeons reported a significant improvement in cutting quality. The complaint rate fell considerably and the scissors were rated as durable and reliable.
The B&W process
When a medical technology company approaches us with a challenge, we rely on a structured development process.
Personal contact is our top priority. We visit the customer, analyse the problem directly and record all requirements. Close collaboration enables us to understand the exact needs and develop customised solutions.
Our interdisciplinary teams from the fields of mechanics, electronics and software analyse the system from different angles. In this way, we ensure that all relevant factors are taken into account and that optimum interaction is achieved. Digital simulations are a central component of our work. Load tests, kinematic analyses and virtual tests help us to identify potential problems at an early stage and rectify them in a targeted manner before physical prototypes are built. Once the simulations are complete, we put together prototypes, often in our own laboratories. These are tested in real-life conditions to validate their performance and make final adjustments.
Finally, we optimise the design for series production. Manufacturing processes are adapted to ensure economical and high-quality production.
There is no room for compromise in medical technology. We develop surgical instruments so that they prove themselves in practice! Precise, durable and optimised for the surgeon.
– Martin Fischbach
The upcoming trend towards robot-assisted surgery poses new challenges. Instruments need to be even more precise, durable and adapted to the mechanical stresses caused by surgical robots. The resilience of instruments is being further improved by new material technologies. Innovative alloys and reinforced coatings increase resistance and reduce wear. Nanocoatings can minimise friction and improve gliding properties. This ensures smoother movements and reduces the force required by the surgeon. Smart sensor technology will enable instruments to provide real-time feedback. Integrated sensors can be used to monitor mechanical loads in order to predict wear and take preventative measures.
Our customers benefit from a holistic development approach. We want to combine quality, functionality and ergonomics. Anyone who wants to develop or improve surgical instruments will find us to be a partner with a deep understanding of medical requirements.
