Cost Reduction and Quality Improvement in Robotic Surgery Components

This case study details the collaboration between a surgical robotics company and Aptyx to enhance the manufacturing process of components for a next-generation robotic surgery system. The project involved the development of 26 components over two phases, addressing issues related to the original brass gear assembly, which was costly and labor-intensive. Aptyx applied its expertise in polymer materials and injection molding to modify the design, resulting in the use of injection-molded plastic components. The first phase introduced a new wheel design that eliminated costly manual operations, achieving over 80% cost savings. The second phase involved complex components with tight tolerances, requiring advanced Moldflow analysis and precise mold designs. The transition from brass to polymer gears not only reduced costs but also improved production times and product quality. The case study emphasizes the importance of design for manufacturability principles and the effectiveness of Aptyx's project management and technical expertise in meeting production demands.