{"id":3805,"date":"2025-06-18T12:01:39","date_gmt":"2025-06-18T10:01:39","guid":{"rendered":"https:\/\/buw-engineering.de\/erfolgsgeschichte\/surgical-precision-robotically-assisted\/"},"modified":"2026-01-21T12:31:28","modified_gmt":"2026-01-21T11:31:28","slug":"surgical-precision-robotically-assisted","status":"publish","type":"erfolgsgeschichte","link":"https:\/\/buw-engineering.com\/en\/erfolgsgeschichte\/surgical-precision-robotically-assisted\/","title":{"rendered":"Surgical precision, robotically assisted"},"content":{"rendered":"

A tool for the future of medical technology<\/span><\/h2>\n

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In modern surgery, precision is not an option, but a prerequisite. Every detail counts, especially in minimally invasive, robot-assisted procedures\u2014from the robot’s first control pulse to the movement at the active tip. Our task: the complete mechanical development of a medical device that not only meets this precision requirement, but also sets new standards.<\/span><\/p>\n<\/p>\n

The project began with a clear goal \u2013 maximum reliability, highest precision, and uncompromising sterility \u2013 implemented in a compact, robust, and user-friendly system. What initially appeared to be a classic design project quickly became an interdisciplinary challenge: motion mechanics in a very confined space, repeatable interfaces to robotics, materials with maximum long-term stability \u2013 and all this under the requirements of a strict regulatory framework.<\/span><\/p>\n<\/p>\n

The core of the system is the highly precise motion transmission, which has been optimized via a complete 3D tolerance analysis from the robot interface to the active tip. No play, no deviation\u2014every micrometer counts. Through targeted compensation tolerances and intelligent coupling concepts, we have ensured that the instrument functions reliably even after repeated attachment and removal \u2013 without readjustment.<\/span><\/p>\n<\/p>\n

We are particularly proud of the connection technology we have developed between stainless steel and ceramic. Through targeted adhesive testing with different epoxy and silicone adhesives, as well as mechanical adjustments, we have been able to create a hybrid structure that is suitable for sterilization and remains tight, secure, and functional even after more than 100 autoclave cycles.<\/span><\/p>\n<\/p>\n

Usability? For us, this is not an afterthought, but an integral part of the development process. All interfaces are intuitive to the touch and visually intuitive, and can even be operated with surgical gloves. The instrument can be assembled and cleaned without tools \u2013 in seconds. And hospital staff confirm that this is finally a system that can be used under real conditions \u2013 even under time pressure.<\/span><\/p>\n<\/p>\n

At the same time, we have focused on a design suitable for series production: fewer components, injection-molded design, reduced assembly times\u2014all while maintaining consistent performance. A well-thought-out concept that impresses not only in the operating room, but also in production and service.<\/span><\/p>\n<\/p>\n

The end result is an instrument that makes a difference: technologically precise, easy to understand, and designed for practical use. For us, it is more than just a project\u2014it is a contribution to the future of surgery.<\/span><\/p>\n

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F<\/span>Flexible teams of 5-10 people, B-sample in 3 months<\/span><\/p>\n<\/div><\/div><\/div>

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Altium, SolidWorks, Polarion<\/span><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n

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Precise system development in robot-controlled medical technology<\/span><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n

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B&W not only understood our vision for a surgical instrument, but also made it measurably better. Many companies develop instruments. B&W makes them noticeably better.<\/p>\n<\/blockquote>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/section>

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\n\t<\/i>\n<\/div><\/div><\/div>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'><strong>3D tolerance analysis<\/strong><br \/>\nA complete tolerance chain was established from the robot interface to the active instrument tip. This made it possible to identify and compensate for critical deviations in motion transmission and force vectors. The mechanical coupling between the instrument and the robot arm was optimised in terms of play, alignment tolerances and repeatability, among other things, taking into account the requirements of the relevant standards.<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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\n\t<\/i>\n<\/div><\/div><\/div><\/p>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'><strong>Adhesion tests<\/strong><br \/>\nThrough systematic adhesion tests with various epoxy and silicone adhesives and mechanical adjustments, it was possible to achieve a high-strength, long-term stable bond between ceramic and stainless steel components. The adhesion between ceramic and stainless steel remains stable both under mechanical stress (grinding process) and under cleaning and autoclaving conditions.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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\n\t<\/i>\n<\/div><\/div><\/div><\/p>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'><strong>Simulation<\/strong><\/div>\n<div class='wp-block-getwid-image-hotspot__tooltip-content'><\/div>\n<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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\n\t<\/i>\n<\/div><\/div><\/div><\/p>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'><strong>Supplier management<\/strong><br \/>\nComplexity made manageable: In a highly complex supply chain, over 10 suppliers were analysed, grouped and structured in an evaluation model. This made it possible to identify redundancies and reduce dependencies. By consolidating technical specifications and process comparisons, the number of active suppliers was significantly reduced \u2013 logistics costs and expenses fell measurably.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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\n\t<\/i>\n<\/div><\/div><\/div><\/p>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<p><strong>Construction:<\/strong><br \/>\nInjection moulding-compatible design for series production: all housing parts were designed in accordance with the rules for injection moulding-compatible design and specified in accordance with ISO 8015 \u2013 with a focus on demouldability, wall thickness homogeneity and position-accurate snap hook integration. Parting lines, undercuts and slides were taken into account early on in the CAD process \u2013 including vent channels and injection points for minimal warpage tolerance. The adapted tool concept led to a reduction in assembly effort and the number of components.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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\n\t<\/i>\n<\/div><\/div><\/div><\/p>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<p><strong>Functional analysis:<\/strong><br \/>\nUnderstanding the system across all components: A complete functional analysis was carried out for a system with over 50 individual components \u2013 including all movement, force and signal flows. This enabled weak points and potential for optimisation to be identified at an early stage. Kinematic and dynamic simulations were used to model the interaction of the components, enabling critical tolerance overlaps and friction effects to be evaluated at an early stage. Mechanical and electrical interfaces to the robot were analysed and documented, including the transmission path of user commands to the mechanical end function.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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\n\t<\/i>\n<\/div><\/div><\/div><\/p>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<div class='wp-block-getwid-image-hotspot__tooltip-title'>\n<p><strong>Solution finding:<\/strong><br \/>\nA systematic solution-finding process was applied to a variety of technical challenges \u2013 based on root cause analyses, creative concept methods and iterative tests. For example: The critical buckling of the control cable under load was solved by specifically modifying the deflection geometries and selecting a more pressure-resistant sheath material \u2013 validated through testing and simulation. To prevent unwanted RF radiation, a controlled contact guide was developed: insulation zones along the instrument and conductive zones only at the cutting edge.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<p><\/span> <\/a> <\/div>
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<\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/section>\n","protected":false},"excerpt":{"rendered":"A tool for the future of medical technology In modern surgery, precision is not an option, but a prerequisite. Every detail counts, especially in minimally invasive, robot-assisted procedures\u2014from the robot’s first control pulse to the movement at the active tip. Our task: the complete mechanical development of a medical device that not only meets this...","protected":false},"featured_media":2921,"template":"","meta":{"_acf_changed":false},"class_list":["post-3805","erfolgsgeschichte","type-erfolgsgeschichte","status-publish","has-post-thumbnail","hentry"],"acf":[],"_links":{"self":[{"href":"https:\/\/buw-engineering.com\/en\/wp-json\/wp\/v2\/erfolgsgeschichte\/3805","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/buw-engineering.com\/en\/wp-json\/wp\/v2\/erfolgsgeschichte"}],"about":[{"href":"https:\/\/buw-engineering.com\/en\/wp-json\/wp\/v2\/types\/erfolgsgeschichte"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/buw-engineering.com\/en\/wp-json\/wp\/v2\/media\/2921"}],"wp:attachment":[{"href":"https:\/\/buw-engineering.com\/en\/wp-json\/wp\/v2\/media?parent=3805"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}