Orthopedic Drill

Challenge
For orthopedic surgeons performing multiple operations in a day, hand tools that are powerful and precise are a must. Additionally, a smaller, more lightweight version of the tool would be a welcome relief. Our customer was launching a new line of surgical hand tools – a drill/reamer, an oscillating saw, and a reciprocating saw – for use in orthopedic and trauma surgeries.

Foremost among the customer’s selection criteria, the customer sought a motion solution that enabled longer life for their hand tools. To this aim, their specific requirements included a minimum of 1,000 autoclave cycles, as well as an improvement in the ease of ball bearing replacement during service relative to the incumbent motor supplier. By improving the life of the new generation surgical hand tools, the customer would be able to truly add value for the hand tool users through reduced replacement costs.

Portescap Solution
Portescap designed four custom slotted BLDC motors to meet the customer’s needs for their respective tool applications. Each of the custom motors featured open front and back ends to facilitate easy ball bearing maintenance. Remarkably, despite the unsealed ends, Portescap was able to design unique material and process modifications that enabled the motors to withstand more than double the number of autoclave cycles required by the customer! Our expertise in sterilizable brushless motor technology, in combination with our customization capabilities allowed us to collaborate with our customer to create a complete customized solution.

Result
The unique motor design resulted in a winning solution for the customer that achieved in excess of 2,000 autoclave cycles (according to customer test reports), compared to just 400 cycles achieved by the competition. In addition, Portescap’s open design enabled much improved serviceability of the ball bearings. Our design achieved stringent sterilization requirements without compromising any performance in terms of torque, speed, or efficiency.

Portescap’s custom sterilizable design capabilities greatly enhanced the life of the customer’s product, satisfying a primary customer need and truly demonstrating that when customers talk, we listen!

About Portescap solutions for the Medical Market
Portescap is the leading supplier of autoclavable Brushless DC motors for powered surgical instruments - life tested by our customers to withstand in excess of 1,000 autoclave cycles. Our motors are found in the industry's leading drills, saws, shavers, screwdrivers, and dental instruments serving orthopedic, cranio-maxillo-facial, ENT, otolaryngological, spinal and neurological surgical applications, as well as general dental and endodontics applications. Our sealing and optimized design assure adequate autoclaving and prevent contamination. So surgeons, and their patients, have a lot to feel comfortable about.