Symmetry’s Cobra Lighted Retractor

How HaA PD Enhanced Visibility in Hip Procedures by Engineering Symmetry’s Cobra Lighted Retractor

Problem

Symmetry needed a reusable acetabular retractor with an integrated LED light source to improve visibility during hip surgeries. The device required embedded electronics, intuitive battery insertion and removal, and compatibility with sterilization—all without compromising ergonomics or surgical workflow.

Solution

HaA PD designed a lighted retractor with a rubberized battery grip, tactile locking feedback, and clear labeling for ease of use. We optimized LED placement to reduce glare and enhance focus within the surgical field. The final design featured intuitive one-hand actuation and reliable sterilization compatibility, improving surgical precision and workflow.

Outcome

We created a low-cost, first of its kind lighted hip retractor with variable light intensity, which was capable of being autoclaved.

This lighted retractor is particularly beneficial in complex surgical environments where optimal lighting and precision are critical. By incorporating Symmetry's Cobra Lighted Retractor into their surgical tools, healthcare providers can significantly improve the efficiency and safety of their operations.

In addition to its clinical benefits, this device reduces cost for the hospital by allowing for reuse, while maintaining required surgical sterilization requirements.

Services Provided to Develop Symmetry’s Cobra Lighted Retractor

User Feedback

  • As a part of our integrated user design process, we gathered all existing documentation from symmetry, which they previously obtained from Physicians while using competitive devices.

Usability

  • We observed multiple procedures, which included videos from competitive devices to understand and create a user flow chart (Procedural map). This included worst case scenarios and potential failure modes.

Engineering

  • As part of our medical device development services, our team worked with Symmetry’s product development team to create the PRD (Product Requirements Document). The requirements were signed off on and our team began concepting assembly methods to optimize manufacturing taking into account all aspects of human factors. These included a battery, PCB and a flex ribbon running to the distal end where a LED light was attached. We also included form studies to optimize leverage and tested for strength. At the conclusion, we provided the client with a cost bill of materials prior to initial production.

Prototyping

  • We procured a PCB flex ribbon assembly, 3D printed silicone handle, battery, LED light, variable dial component and machined metal center beam. 

Manufacturing

  • We worked with the Symmetry manufacturing team at the factory to review all existing equipment and recommend the purchase of new equipment required to produce the device in house. The purpose of the new equipment purchases was to reduce production cost and ensure quality.