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Reusable Perforator Sleeve

The Codman Disposable Perforator is a single use, cranial access perforator for neuro surgery. It is designed to automatically disengage once successful skull perforation is achieved, to prevent injury to the brain tissue.

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The reusable sleeve is a project I proposed and developed that improves ergonomics and minimizes material waste, reducing the amount of perforator sleeves and bearings used by 50%.

Project Overview

  • 1,000+ perforators are test-drilled daily

  • Perforators are then disassembled and cleaned

  • Disassembly requires removal and disposable of the plastic sleeves that hold the assemblies together

  • I proposed and designed a reusable perforator sleeve

  • Fits all 3 perforator sizes

  • Eliminates need to discard 1,000+ sleeves daily

  • Estimated to save $100,000+ annually

  • Eliminates ergonomic risk associated with sleeve removal

Perforator with Reusable Sleeve

Perforator with Molded ABS Sleeve

Molded ABS Perforator Sleeve SolidWorks Model

Reusable Perforator Sleeve SolidWorks Model

Nylon Bushing SolidWorks Model

Design Process

  • Started by modeling the old molded sleeve on SolidWorks

  • Added a hinged tab to replace the plastic weld

  • 3D printed 1st prototype to test functionality using nut/bolt locking mechanism

  • 5+ revisions to improve print tolerance, hinge design, and locking mechanism

  • Decided on O-ring locking mechanism for manufacturability and ergonomic ease

  • Offset O-ring nubs and added top handle for easy opening

  • Incorporated the shape of the molded nylon bushing (used with molded sleeve) into design, by 3D printing the entire sleeve out of nylon

Design Challenges & Solutions

  • Must stay keep perforator assembly together

  • Must be removable

  • Must function same as old sleeves

  • Designed same shape with hinged tab

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  • Must be easy to assemble/ not an ergonomic risk (considering 1000+ repetitions daily) 

  • Must never come apart while drilling

  • Tried a threaded cap but was difficult to 3D print 

  • O-ring solved all these issues

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  • Must be durable enough to withstand extended use

  • Must be easy and cheap to manufacture

  • Nylon bushing might get stuck in sleeves after testing

  • 3D printed nylon sleeve in-house with built-in bushing

Reusable Perforator Sleeve Assembly Process

Reusable Perforator Sleeve Assembly Fixture Model (Top) & Actual (Bottom)

Further Steps

  • Designed assembly fixture to aid assembly and ensure proper alignment of all components 

  • Wrote and executed test method validation for the reusable perforator sleeve.

Reusable Perforator Sleeve Assembly Fixture Function

Additional Images

Click on images for description.

Other JnJ Co-Op Projects:

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