DePuy Synthes

DePuy Synthes

Designing single-use instruments for orthopaedic surgery


Knee replacements are big business. DePuy Synthes, a leading manufacturer of orthopaedic implants, leases reusable surgical instrument sets to hospitals for joint replacement surgeries.The sets cost $30,000–$100,000 and were only compatible with one model of implant: this high cost to the industry skewed the business model and reduced flexibility and development.


DePuy Synthes sought Innovia’s help in creating disposable versions of the two most complex instruments in the set. The disposable instruments needed to be low-cost, as accurate as the stainless steel version, and at least as acceptable as familiar reusable instruments to orthopaedic surgeons. This last demand was the toughest: previous prototypes had failed on this requirement.


In just eight weeks, the Innovia team designed, modelled, and created ten working prototypes for the devices. The prototypes met the technical needs, and the surgeons preferred the simple design of the disposable instruments. With Innovia’s help, DePuy Synthes is leading the instrument marketing revolution.