Background
Laparoscopic surgery requires precise control at the distal tip through small access points. To make control more intuitive, our team explored a bendable tool section that mimics index finger movement. I owned the development of the motor and bearing housing that serves as a connection between the tip and the handle.
The primary engineering challenge was packaging a motor and bearing reliably inside a comfortable, hand-held handle while preserving clearance for internal mechanisms. The shape of the housing also had to consider the usability to align the distal tip with user’s index finger.
Approach
I owned the 3D CAD work for the motor and bearing housing, which also connected the distal tip to the handle. I iterated the design in Autodesk Fusion 360. The work moved from system-level layout to focused connector studies and then to housing iterations. Each iteration was tested with resin 3D prints for easy assembly and whether the motors and bearings could coexist inside the housing. The exterior shape of the housing evolved from rectangular to curved design to reduce weight and blend in with the rest of the grasper.
In addition to the 3D CAD work, I was assigned to program the Arduino controllers to optimize encoder–motor communication and to perform reliability testing on the motor. Fast encoder–motor communication was important to the grasper for the distal end to replicate the motion of the user’s index finger without significant delay for accuracy and user experience. Using Six Sigma principles, I was able to perform reliability testing on the motor across 50+ cycles.
Impact
The final 3D CAD design reduced the weight of the housing and showcased rapid prototyping. Arduino controller work improved encoder–motor response by 50%. The project reinforced that ergonomic intent and component packaging must be developed together.
By working with the team internationally and through weekly presentations, I enhanced my communication and collaboration skills and learned the importance of a team having the same vision.
