Methods
We have many great examples of how research helped our medical product design team realize opportunities for innovation. A great case in point is our medical product design of a new set of spinal surgery tools.
The Blackstone Spinal Surgery Tool Set is a comprehensive set of ergonomic tools to perform all spinal surgeries in an effective and safe way. The set of tools has been designed specifically for orthopedic surgeons with a particular attention to the changing demographics of surgeons worldwide. The tools have been designed to minimize the risk of repetitive motion injuries, shoulder abduction, wrist deviation and general muscle fatigue very common with poorly designed surgical tools as well as legacy surgical tools.
Traditional surgical products, especially orthopedic surgical tools, have been used for decades by medical professionals. The product design was primarily driven by the need to achieve a particular complicated medical task with very little respect to ergonomics and comfort during use by medical professionals. Blackstone realized there was an opportunity to simplify and streamline the surgeon’s workload and ultimately minimize their risk of repetitive injuries through effective design of these medical products.
Our research team started with a thorough review of the wide range of existing devices. The legacy medical product line grew through the years as procedures proliferated and generations of surgeons adopted new techniques. Our PhD led product design team drove new instrument configurations and handle forms. The team then took first generation product design models into the cadaver lab to try them out first hand and get feedback from consulting surgeons. In parallel the product design group defined the new brand identity, including, dimensional logo treatment, color and graphics and texture.
The biggest challenge was to enable all of the required usability across an extremely wide range of tools while creating a common brand language. Further complicating the process, all tools had to be autoclaved so product material selection had to be considered accordingly, creating challenges for complex mechanical assemblies. This led to a wide range of materials and processes including:
- Multi-color cast silicone rubber for the handles and graphics
- Machined stainless steel for all tools with laser etched graphics
- Anodized titanium for surgical screws and tool color coding collars
- Machined and anodized aluminum for the carrying cases with pad-printed graphics
- Injection molded ABS plastic for the corner of the carrying cases
The new product line provides Blackstone with a competitive advantage of delivering a more ergonomic solution than their competitors. Reducing fatigue during surgery (which can last up to 8 hours) ultimately ensures the highest level of care can be provided to the patient with greater accuracy, reliability, within the shortest amount of time. Less stress during surgery usually means an easier path to recovery. In addition the new design supports the Blackstone Medical Branding strategy and provides a unified product identity reinforcing the Blackstone core values of quality and reliability.