Biomechanical Evaluation of a Spinal Surgical Instrument: A Numerical–Experimental Approach

Background/Objectives: The conventional practice in clinical settings involves using multi-use surgical instrumentation (SI). However, there is a growing trend towards transforming these multi-use SIs into disposable surgical instruments, driven by economic and environmental considerations without considering the biomechanical aspects. This study focuses on redesigning an SI kit for implanting cervical spinal facet cages. Understanding the boundary conditions (forces, torques, and bending moments) acting on the SI during surgery is crucial for optimizing its design and materials. Therefore, this study aims to develop a measurement system (MS) to record these loads during implantation and validate it through in vitro testing. Methods: A combined numerical–experimental approach was used to design and calibrate the MS. Finite element analysis (FE) was used to optimize the geometry of the sensitive element of the MS. This was followed by the manufacturing phase using 3D printing and then by calibration tests to determine the stiffness of the system. Finally, the MS was used to measure the boundary conditions applied during SI use during in vitro tests on a cervical Sawbone spine. Results: After designing the measurement system (MS) via finite element analysis, calibration tests determined stiffness values of KF = 1.2385 N/(µm/m) (axial compression), KT = −0.0015 Nm/(µm/m) (torque), and KB = 0.0242 Nm/(µm/m) (non-axial force). In vitro tests identified maximum loads of 40.84 N (compression) and 0.11 Nm (torque). Conclusions: This study developed a measurement system to assess surgical implant boundary conditions. The data will support finite element modeling, guiding the optimization of implant design and materials.