Hip Implant Instrument Redesign
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Date
2015-12-07
Authors
Penner, Trevor
Chan, Chi Kit
Borovytskyy, Martin
Jacobson, Natasha
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Abstract
The objective of this project, as specified by the sponsoring client, the Winnipeg Regional Health Authority (WRHA), was to redesign a hip implant trial kit including the trial spacers, trial heads, trialing tools, extraction tool, and carrying case, to improve the reliability of sterilization of the trial kit and to increase the durability of its components. This redesign included the creation of a realistic and feasible manufacturing process for each instrument, evaluation of possible failure modes and preventive actions, a clearly defined cleaning process, as well as a complete CAD model for the set. To redesign the existing set, preliminary analytical and numerical analysis were completed, and the design team selected a threaded spacer design as the final concept. The final materials chosen for the spacer, trial head, and trialing tools were chosen using a similar process, resulting in PEEK 90HMF40, Delrin 100P and 316 series stainless steel, respectively.
Having optimized the design further through iterative calculations and numerical analysis, the final dimensions of the thread were a M30x5 thread with a 15 mm lead. All other dimensions were made similar to existing product dimensions, and validated through numerical and analytical analyses. In addition, a failure analysis was performed and the results were used to create a quality assurance plan to prevent catastrophic failure due to fracture.
A hip implant trial kit has been redesigned to meet all of client objectives and remain within constraints. In addition to the redesign, a feasible manufacturing plan for each component, an analysis of possible failures, a sterilization process, and a complete set of engineering drawings for the set have been completed. Furthermore, a possible interim solution was provided to immediately improve existing product use and efficiency.