Ergonomic Redesign of the Needle Driver for Quality Compliance and Comfortable Surgical Performance

The needle driver is a critical surgical instrument used in suturing procedures. However, traditional designs present ergonomic challenges that can lead to discomfort, inefficiency and potential musculoskeletal disorders(MSDs) among surgeons. This study focuses on identifying these limitations and proposing a redesigned needle driver that enhances usability while maintaining quality compliance. Through qualitative research conducted at the University of Illinois Chicago, feedback from medical and surgical residence was collected via surveys, focus groups and interviews. The findings highlighted several key issues, including proper tool fit, hand fatigue, difficulty in tool handling and safety concerns related to needle slippage and improper grip. Additionally, left-handed surgeons face challenges using right-handed instruments and variations in hand sizes or often overlooked in existing designs. To address these concerns, the study proposes an ergonomic redesign featuring adjustable ring handles and rod lengths to accommodate different hands lengths and improve grip stability. The redesign incorporates bayonet mount mechanism, allowing for secure and easy adjustments without compromising the stability of the instrument. This new design aims to reduce hand strain, enhance precision and improve overall surgical efficiency. Despite its advantages, the redesigned needle driver presents challenges such as potential mechanical failures in threaded components and contamination risks exposed areas. Future work will focus on validating the design using biomechanics simulation software and 3D hand scans to ensure effectiveness in reducing hand fatigue and enhancing surgical performance. The proposed innovation aims to set a new standard for ergonomic and high-performance surgical tools.