Digitalizing Surgical Tools for Real-Time Spine Surgery Monitoring

Digital technologies are bringing real-time data and intelligent monitoring directly into surgical environments. A European medical technology company partnered with T&S to digitalize surgical tools used during spine procedures, integrating sensors, embedded electronics and data-transmission into instruments to help surgeons better control applied force and reduce the risk of screw pullout during vertebral fixation. Combining mechanical engineering, embedded systems, software and medical-device expertise, T&S supported the full realisation from concept to industrialisation support.

Client context

The client, a medical-device manufacturer specialising in spinal surgery, wanted to enhance surgical precision through connected instrumentation delivering real-time operational feedback. Traditional tools gave limited visibility into forces applied during critical fixation phases, so the client sought digital monitoring within the surgical workflow without disrupting usability, ergonomics or clinical practice - integrating advanced sensing and transmission into compact instruments while maintaining reliability, sterilisation compatibility and regulatory readiness.

Business challenges

• Embed measurement capabilities into highly constrained mechanical environments with accurate, real-time data transmission
• Address hardware miniaturisation, sensor integration and mechanical robustness simultaneously
• Coordinate hardware, software and mechanical integration within a compliant medical-device framework
• Enable rapid prototyping for fast concept validation and iterative development
• Anticipate industrialisation from the earliest design phases for scalability and manufacturability

The T&S solution

T&S delivered an end-to-end engineering approach covering ideation, proof-of-concept, full product realisation and industrialisation support. It began with concept definition to identify suitable sensor technologies, data-transmission architecture and mechanical integration strategy. A proof-of-concept phase validated feasibility: T&S developed acquisition and transmission boards, implemented embedded software and created a supervision interface for real-time monitoring during testing. Mechanical teams ran 3D studies and integration analyses to embed electronics without compromising ergonomics or performance. After validation, T&S integrated mechanics, hardware and software into a unified connected medical-device ecosystem, with industrialisation and medical-certification support to prepare for deployment.

Technologies & expertise

• Creo CAD
• Altium Designer
• Bluetooth Low Energy (BLE)
• Python
• Embedded acquisition systems
• ISO 13485

Results & business value

• Successful digitalisation of spine-surgery tools with real-time intraoperative monitoring
• Improved visibility into force application during vertebral fixation, supporting reduced screw-pullout risk
• Faster technical validation and reduced development uncertainty via the proof-of-concept approach
• Demonstrated how connected medical technology improves surgical workflows while preserving usability

Conclusion

The project highlights T&S's ability to develop complex connected medical devices combining mechanics, embedded electronics, software and industrial engineering, transforming conventional surgical tools into intelligent connected devices for safer, more data-driven procedures.