Revamped Cautery Unit Puts Heat on Electrosurgical Devices

Originally Published MDDI June 2002

MEDICAL DESIGN EXCELLENCE AWARDS 2002

Thermal Cautery Unit, Model 150

Submitted and manufactured by Geiger Medical Technologies Inc. (Monarch Beach, CA)

What does Geiger Medical Technologies Inc.'s Thermal Cautery Unit (TCU) Model 150 have in common with today's sleek, sporty cars? Both products exhibit contemporary shapes and lines, which, in the TCU's case, are the result of a complete product design overhaul completed by a graduate of the Art Center College of Design (Pasadena, CA), a school renowned for its state-of-the-art automotive design curriculum.

When Geiger Medical decided it was time to revamp its sole product offering, which hadn't been updated in more than 40 years, a new design was a key goal. "We needed a new look for technology that basically hasn't changed much in decades, but it had to appeal to our current core audience of dermatologists, surgeons, and veterinarians while also attracting new customers in ENT, urology, plastic surgery, and in international markets," explains John Bottjer, president of Geiger Medical. "We needed a 'wow' factor, because it was becoming harder to sell the device based on its old-fashioned appearance. In Detroit, they're always seeking the 'wow' factor on a grand scale, so we sought out someone who could do the same for our product."

The device, which is used to stop bleeding and destroy lesions by applying high levels of heat via a wire, was able to remain unchanged for so long largely because Geiger Medical is the only U.S. manufacturer of such units. However, company research showed that the device had many other applications that could be capitalized upon.

"Many physicians feel that there is less tissue destruction with thermal cautery units than with devices on the next level of care: high-frequency electrosurgical units. Patients also experience less pain, faster healing, and fewer scars," Bottjer says. "Further, radio-frequency currents associated with electrosurgical units can disrupt the operation of pacemakers and implantable defibrillators. Disposable cautery units, which are one step below our device, can't maintain constant temperatures of 2200°F, which are needed for treatment. We had the potential to truly grow our market if the device's appearance was updated and we could move away from the hand-crafted design the company had followed for decades, which limited the number of devices we could produce.

"Before, the unit was basically a transformer in a box," Bottjer continues. "Now we've completely updated all of the electronics, and the device consists of a printed circuit board that is stuffed in a gray plastic, injection-molded clamshell housing. We can make thousands easily."

The company also sought to increase the simplicity and ergonomics of the device. Now the TCU sports one handpiece connector (rather than the two in the previous version) and combines the formerly split handpiece cables into a single, easily cleaned, flexible, multiple-wire cable. The handpiece features grip grooves for improved handling, as well as a taller activation button that is more accessible to gloved fingers.

The TCU also offers improved operation. In the original design, internal components could self-destruct as the device reached its 2200°F threshold; now the heat-resistant plastic housing and a stainless-steel shroud that pulls heat away from the handheld button area solve that challenge.

Both the company's core markets and potential markets have responded positively to the improvements—sales are up nearly 600% in the new TCU's first year of production. MDEA judges liked the improvements, too: "The whole redesign emphasizes good industrial and human factors engineering," says Corinna Lathan, an MDEA juror.

With sales of the TCU Model 150 exceeding all expectations, Geiger Medical's Bottjer, like Detroit, is already planning future offerings. "We expect to introduce other products soon," Bottjer says, adding that more sleek device designs are on the way.

Copyright ©2002 Medical Device & Diagnostic Industry