Design Process

This project required our team to design a system that could transfer and secure a surgical tool into a set autoclave for sterilization. I was on the modeling sub-team which meant our team was responsible for designing a container for the specified tool, the suction. Our constraints/objectives were:

• All features must be more than 2mm;
• Must not exceed given autoclave footprint;
• Must securely hold surgical tool;
• Must be able to sterilize tool effectively;
• Should be easily transferred by the robot arm's end effector (Q-arm);
• 3D Printing time must be under 2 hours.

Once we determined the main objectives, we began sketching several prototype sketches to brainstorm ideas for the container design. After gathering a few solid features we liked, we created low fidelity prototypes to see what worked and what did not.

My low fidelity prototype of the sterilization container

Assigned surgical instrument: suction

In the end, both low fidelity prototypes were lacking the functional security of the tool as well as used unnecessary excess materials so we went back to the drawing board. This made me realize first iteration of ideas or designs don't always work. Once we figured out better designs, we moved onto the medium fidelity prototype of CAD modeling our prototypes into Inventor.

My medium fidelity prototype refined to fit our tool better. Chosen to be finalized and refined.

Finalized sterilization container

Through many refinements and feedback from both our team and IAIs, we created the finalized product as seen above. There were some issues we had to fix. One was that the container not fitting properly in the autoclave footprint and had to readjust the sketch appropriately. The tool was not being secured properly in the original so we added two extrusions to fasten it in place. Some features that were 2mm were increased to prevent breakage during 3D printing

Here are the features of our finalized model:

• Follows the shape of the given tool and chamfered the edges to minimize material
• Two extrusions/security bars to hold the suction in place during transfer [red]
• Holes for proper sterilization [green]
• Protruding edge around the top for easy grip of the container [blue]

Finally, we assembled all the components together (seen below) and printed the finalized container.

All parts assembled (suction, container, and footprint)

Concluding Remarks

For this project, I was one of the Administrators of the team meaning that I was responsible for the submission of milestones and mainly in charge of the modeling sub-team. Although I did not get to spend that much time with the computing sub-team, it was exciting to see everything slowly come together in moments where we got met together and discussed this project.