The most common surgical implant is a screw; surgeons insert billions of them in patients each year.

Screws need holes, and holes need drills. When wielding these drills, "Surgeons currently use their 'feel' to stop on the far side of the bone," writes McGinley Orthopedic Innovations. Because that "feel" can leave a lot up to chance, company founder Dr. Joseph McGinley conceived of an Intellisense Drill Technology. This would "automatically stop the drill motor upon breach of the desired cortex. This may help ensure that critical structures past the bone are not damaged."

To actually develop this technology and get it into a physical product, McGinley tapped industrial design & engineering consultancy Speck Design. "Our team collaborated closely with Dr. McGinley to turn a visionary idea into a tangible, innovative product that simplifies orthopedic surgeries," writes Speck. The goal was to "transform orthopedic surgeries with IntelliSense Drill Technology® for enhanced safety and efficiency."

Industrial Design

We crafted a design that merges advanced functionality with ease of use, tailoring the drill to the demanding environment of surgery.

The industrial design process focused on creating a product that not only met the rigorous demands of surgical environments but also enhanced the user experience for surgeons. By meticulously studying the workflow and needs of orthopedic surgeries, we designed the IntelliSense Drill with ergonomics, precision, and reliability at the forefront. This design philosophy ensured the drill was intuitive to use while incorporating advanced functionalities that set new standards in surgical tools.

Electrical Engineering

Integrating smart sensor technology to automate and refine the drilling process, ensuring unparalleled precision and safety.

The IntelliSense Drill's breakthrough comes from its advanced sensor technology, meticulously integrated by our electrical engineering team. This innovation allows for real-time bone penetration detection, halting the drill instantaneously to prevent over-drilling. Our engineers focused on creating a seamless interface between the drill's mechanical functions and its intelligent sensing capabilities, ensuring that the technology was not only effective but also reliable and easy for surgeons to use in high-stakes scenarios.

Mechanical Engineering

Engineered for precision, the drill's mechanical components are designed to respond flawlessly to the intelligent sensor system.

Our mechanical engineering efforts were centered on ensuring that every component of the IntelliSense Drill was optimized for both performance and safety. By developing a mechanical system that works in perfect harmony with the drill's sensor technology, we ensured that surgeons have a tool that delivers precise depth measurements and automatic stopping mechanisms. This level of engineering precision guarantees that the IntelliSense Drill can offer consistent and reliable performance in the diverse range of procedures it's used for, making orthopedic surgeries safer and more efficient.

User Testing

Conducted comprehensive user testing to validate design choices and ensure the product meets surgical needs effectively.

A pivotal aspect of our project was extensive user testing, which involved gathering feedback from orthopedic surgeons to validate our design and engineering choices. This phase allowed us to refine the product further, ensuring that the IntelliSense Drill not only met but exceeded the practical and ergonomic requirements of its users. Testing in real-world surgical scenarios provided invaluable insights, leading to adjustments that enhanced the drill's usability, functionality, and overall acceptance within the medical community.

You can see more of Speck's work here.