Evergreen Orthopedic Research Lab

Instrument Design

Instrument Design and Evolution

Evergreen Orthopedic Research Lab (EORL) designs, manufactures, and distributes the specialty instruments that today’s ever-changing surgical techniques require.

Surgeon Innovations

The ideal way to create new surgical instruments is to put talented, innovative surgeons together with engineers in an environment where they can develop and test their ideas. EORL’s team of engineers, CAD artists, tissue specialists, and ISO-9000 certified manufacturers work closely with design surgeons to create innovative solutions for advanced surgical techniques. At EORL, the entire process from conception to the manufacture and sales of innovations evolves seamlessly. Our goal is to enable surgeons to design and manufacture the instruments that can make their surgeries easier.

Designer Surgeon Meetings

EORL sponsored “Matrix Surgeon Meetings” gather community thought leaders to discuss and debate the validity of new surgical techniques such as MIS methods, hip resurfacing, computer navigation, shape-fit technologies, and others. These meetings identify meaningful improvements in surgical technique. They also target the needs for and provide the design inputs for new surgical instruments. Surgeons on the EORL design team meet with EORL engineers and developers to fine tune and improve instruments at each phase of instrument development.

Spokane surgeons and designers discussing instrument needs for MIS hip replacement and "The Spokane Hip Project."

Initial Concept Development

3D Computer Modelling

New concepts are translated into computer models. These precise 3D models enable surgeons and engineers to visualize and evaluate new instruments critically and efficiently. On-line meetings eliminate the need for costly and time-consuming travel.

The Matrix Tibial Resection Guide integrates balancer methods and computer navigation for MIS TKR and partial knee replacement.

Rapid Process Prototyping

With the concept details captured in a computer model, Rapid Prototyping Techniques are utilized to quickly iterate through concept refinements. Resin, plastic, or metal models are fabricated depending on the application. EORL can utilize rapid process prototyping to create plastic and resin models.

Composite Resin Model of the Matrix Distal Femoral Cutting Guide (patent pending).

Design surgeons and engineers can then see how the instrument is likely to perform in a live surgical setting.

They can be manipulated and trialed with existing devices. This process helps refine ideas and saves considerable time and money.

Dr. Richard Roux demonstrates ideas for improvements in the Kirkland Bullet (patend pending).

The EORL Artificial Hip and Knee as well as the EORL Cadaver Table enable surgeons quick and cost effective access to a simulated surgical setting. The prototype instruments can be manipulated, trialed, and validated with computer navigation. In this setting, surgeons and engineers refine the concepts into fully functional instruments. These models are combined with the EORL artificial knee and hip (patent pending) and the EORL cadaver table (patent pending).

The EORL cadaver table (patent pending).

The EORL artificial knee (patent pending) being utilized to test MIS total knee instruments.

Engineering, Quality Control, and Manufacturing

Once an innovation’s design is finalized, EORL’s engineers release CAD drawings and initiate verification and validation activities. The instruments are validated in the computer navigation/cadaver lab.

Ultimately, the instruments are manufactured and packaged according to the strictest standards by EORL’s certified manufactures.

CAD Drawing showing engineering details and providing specifications for manufacturing and quality control.

The Lovell Soft Tissue Protectors

Used to protect soft tissues during the Anterior Approach for MIS Total Hip Replacement

The Matrix Femoral Jig for Navigated MIS Total Knee Replacement

The Matrix Tibial Jig for Navigated MIS Total Knee Replacement and Unicondylar Knee Replacement

The Roux-McAllister Saguaro Cactus for Percutaneous Placement of Trackers for Navigated Joint Replacement

The Matrix Precision Pins

The Matrix Pins have sharp tips that allow precise placement. Unlike drill bits, bone is compressed rather than removed, decreased the potential for stress risers. Only one cortex is penetrated, and pins can be accurately replaced for “re-cuts.” The Matrix Pin helps improve the stability of cutting blocks and the accuracy of bone cuts during navigated or non-navigated surgeries.