JustRightâ„¢ 5mm Pediatric Stapler

The challenge

Standard laparoscopic surgical staples are used to divide tissue planes in minimally invasive surgical procedures. Staples are used instead of sutures for these procedures as they are both easy to use and can fit into tight spaces. The standard for these staples is 10mm in length and as such, require a stapler sized accordingly. While this may be sufficient for use in adult patients, it does pose quite a challenge when using the same device in pediatrics. In an effort to address this challenge, surgeons are forced to alter the way they perform certain procedures on pediatric patients, increasing the risk of complications to the patient. Synectic was approached to develop a surgical stapler for use in pediatric patients. The biggest challenge was incorporating the current regulatory compliant standard 10mm staple into a 5mm stapler, while still applying enough clamping force to correctly form the staple. 

pediatric stapler tip comparison

pediatric stapler packaging

Synectic's solution

Synectic first performed a feasibility study to determine if reducing the stapler anvil size, while keeping the staple size the same, was even possible. Once it was determined that the design was feasible and what forces would be required to successfully form a 10mm staple, Synectic reviewed and chose materials that would employ optimal strength while still passing biocompatability and sterility parameters. To accommodate smaller tissue sizes, the stapler head was modified from the classic 6 rows of 6 staggered staples to 4 rows, but still maintain a secure staple line. While our mechanical engineers developed the stapler and anvil head, our industrial designers designed an intuitive handle design that employed additional safety features to assist surgeons in case of misuse. Additionally, the stapler shaft was designed in such a way to allow for easy replacement of stapler cartridges. Finally, clinician friendly packaging was designed and tested. 


The result

  • A pediatric stapler that can fit into tight spaces, reducing port size from 12mm to 5mm, decreasing procedural time and patient harm. 
  • An intuitive handle design that allows surgeons to manually disengage the stapler as well as easily replace stapler cartridges. 
pediatric stapler

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