Surgical robotics has come a long way, but even cutting-edge systems have room for improvement. The HUGO robotic-assisted surgery system, developed by Medtronic, is an impressive piece of technology, but its current design is bulky and visually unappealing. Its scissor-like joints make it look more like an industrial machine than a refined surgical tool. This project aims to change that by giving the robotic arm a sleeker, more compact cylindrical design that minimizes bulk while maintaining functionality.

Stepping Outside the Traditional Mechanical Role

As part of CU’s senior design team, I volunteered to take on an electro-mechanical engineering role—an unconventional path for someone with a mechanical background. I’ve always been fascinated by circuits, wiring, and how electronics bring mechanical systems to life. This project allows me to step beyond traditional mechanical design and integrate electrical and mechanical elements into a single, functional system.

Working with Medtronic, a leader in surgical device innovation, adds another layer of excitement and responsibility. Our goal isn’t just to refine the robotic arm’s appearance—it’s to create a design that seamlessly fits into surgical environments, enhancing both usability and aesthetics.

Pretotyping—Solving Z-Axis Movement Without Complex Math

Before committing to the fully 3D-printed version, I built a pretotype using wooden dowels and hot glue. The goal was to determine if the arm could achieve a linear Z-movement while keeping the tip on a straight path. Initially, we anticipated needing complex mathematical calculations to determine the correct servo angles for smooth vertical motion.

However, I discovered a far more efficient solution. Instead of solving for the angles mathematically, I manually mapped the servos to the desired positions, recorded the angles, and used linear regression to create a function that produced linear Z-motion. This method saved us significant time while also proving that we could remove the traditional Z-slide from the existing HUGO robot—an important step toward making the arm more compact and efficient.

Building the Prototype—Solo and Under Pressure

I’m responsible for designing and building a 1:1 functional replica of the improved robotic arm using servo motors and a fully 3D-printed chassis. No external help, no shortcuts—just me, my skills, and a tight deadline.

To accurately mimic the degrees of freedom of the actual manufacturable arm, I incorporated two 25kg-cm servos into my design. The chassis maintains a 1:1 diameter match to the real surgical arm, ensuring realistic spatial constraints and usability testing. The servos are controlled by an Arduino and a Python script, which takes input from an Xbox controller. This setup allows the test engineer to experiment with the arm, ensuring that failures are detected early and performance is optimized.

Beyond mechanical validation, the prototype plays a crucial role in testing surgical optimizations, such as cable routing and drape management—critical elements in robotic-assisted surgery. Due to the ongoing patenting process, specific details of these optimizations cannot be disclosed at this time.

Inventing a New Surgical Cable Management Solution

In addition to developing the robotic arm prototype, I have also invented a new method for securing surgical tool cables, preventing them from cluttering the operating room floor. This innovation enhances safety and efficiency in the surgical environment by integrating cable management directly into the robotic arm.

The prototype allows us to test this concept, ensuring that cables remain neatly routed along the arm while maintaining full functionality. This proof-of-concept demonstration is a key step toward validating the design and proving its effectiveness. I am currently in the process of filing a patent through Medtronic for this invention, marking a significant milestone in my engineering career.

What This Project Means to Me

This experience is more than just another engineering project; it’s a testament to my ability to adapt, learn, and push boundaries. It reinforces my belief that mechanical and electrical engineering are deeply interconnected, and mastering both opens the door to endless possibilities.

By the end of this project, I aim to have a refined, functional robotic arm that not only meets Medtronic’s design goals but also proves that innovation doesn’t have to be a team effort—it can be driven by a single, determined engineer.