Case Study
SILS™ Hand Instruments
About the Work
Covidien, now part of Medtronic, is a global leader in minimally invasive surgical equipment. Covidien collaborated with leading surgeons to develop the concept of single incision laparoscopic surgery (SILS), enabling surgical procedures to be performed through a single port. The key challenges to widespread adoption of the SILS™ Procedure were the limited access, maneuverability, and ergonomics of conventional rigid laparoscopic instruments. The Covidien team came to our team at Design by Boyd to develop a line of articulating instruments known as SILS™ Hand Instruments.
Concept Generation
Concept GenerationConcept Evaluation
Concept Development
Concept Refinement & SelectionDesign & Development
Development PlanningRequirements & Specification Definition
Device Design
Device Manufacturing
Risk Management
Documentation
Verification & Validation
Verification & Validation PlanningProtocol Generation
Testing & Test Management
Report Generation
Manufacturing Transfer
Device Master RecordConcept Generation & Development
During Concept Generation and Development, we collaborated with Covidien’s legal team to create new technical concepts for articulating laparoscopic instruments, taking into account the competitive landscape. A number of invention disclosures were generated from this work, which led to a series of utility patents (US 8,801,752 B2, US 9,883,880 B2) to help protect Covidien’s intellectual property. Our device concepts tied articulation to the movement of the handle, allowing the tip of the instrument to function as a natural extension of the handle. We designed, fabricated, and tested benchtop prototypes to evaluate these concepts in vitro. The team at Design by Boyd used the results from this testing to refine the concepts and initiate the Design and Development phase.
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Design & Development
During the Design & Development phase, the team at Design by Boyd developed a design for the SILS™ Hand Instruments, which was based on these refined concepts. We then compiled the design requirements, which were based on input from Covidien doctors who were experts in the SILS field. We were then able to translate these requirements into technical specifications. We conducted industrial design studies in close collaboration with the industrial design team at Covidien to develop an ergonomic handle that enables optimal control. We used injection-molded (plastic and metal) components to build "looks-like" and "works-like" prototypes that could then be used in benchtop studies to evaluate device functionality and clinical effectiveness. We worked closely with the team at Covidien to develop protocols for animal testing. A Design History File (DHF) was created within Covidien's quality management system to document the development process and the final design. We developed detailed design specifications and worked closely with Covidien’s manufacturing team to create a pilot manufacturing line. We also helped create and maintain a risk management file, which provided additional design specifications.
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Verification & Validation
During the Verification & Validation phase, the team at Design by Boyd helped translate the technical specifications into verification and validation testing protocols. We supported all testing, including testing to show regulatory compliance with relevant standards for electrical safety and usability. As part of our work, we assisted Covidien’s regulatory team in preparing their 510 (k) submission (K091869), which was approved to clear the device for commercial sale.
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Outcomes
Covidien successfully commercialized the SILS™ Hand Instruments and generated widespread adoption of the SILS™ Procedure, becoming a global leader in minimally invasive surgical equipment. The Company is now part of Medtronic.
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Intellectual Property Protection
Development of the SILS™ Procedure
Successful Product Launch
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