Project Overview

Case: Unicompartmental Knee Arthroplasty (UKA or UNI) repairs knee damage limited to a single compartment. Unlike total knee replacement, UNI procedures require smaller incisions and disrupt less tissue. As a result, patients recover faster. For these procedures, reliable instrumentation is critical. In addition, surgeons prefer fewer instruments to reduce clutter and confusion in the operating room. For this reason, when the client asked Tri-Power Design to develop instruments for a new UNI system, the tools needed to be both effective and compact. (https://djoglobal.com/our-brands/djo-surgical/empowr/partial-knee)

Solution: From the start, the team focused on modularity and multi-functionality. As a result, Tri-Power Design developed instruments that serve multiple purposes without sacrificing accuracy or quality. For example, a femoral preparation guide confirms sizing, measures the tibial–femoral gap, drills the posterior peg hole, and performs two of the three resection cuts. Similarly, femoral trials support trialing while also guiding the anterior peg drill.

Design Challenges: Although the project presented many challenges, meeting surgeon expectations for fit and function proved most demanding. To address this, Tri-Power Design produced numerous rapid prototypes and several dozen metal prototypes. Surgeons then evaluated these instruments in cadaver labs. Throughout each iteration, the in-house machine shop allowed engineers to fine-tune critical dimensions. The team captured these refinements and fed them back into the 3D CAD models.

Even after transferring final CAD models and drawings to the client for validation and verification, Tri-Power Design remained involved. Specifically, the team manufactured multiple sets of validation instruments, including LMC and MMC parts. As a result, the final instruments continued to meet the original design inputs defined by surgeons.

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