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Design of electrical impedance spectroscopy sensing surgical drill using computational modelling and experimental validation

Electrical Impedance Spectroscopy (EIS) sensing surgical instruments could provide valuable and real-time feedback to surgeons about hidden tissue boundaries, therefore reducing the risk of iatrogenic injuries. In this paper, we present an EIS sensing surgical drill as an example instrument and introduce a strategy to optimize the mono-polar electrode geometry using a finite element method (FEM)-based computational model and experimental validation. An empirical contact impedance model and an adaptive mesh refinement protocol were developed to accurately preserve the behaviour of sensing electrodes as they approach high impedance boundaries. Specifically, experiments with drill-bit, cylinder, and conical geometries suggested a 15%–35% increase in resistance as the sensing electrode approached a high impedance boundary. Simulations achieved a maximum mean experiment-to-simulation mismatch of +1.7% for the drill-bit and +/−11% range for other electrode geometries. The simulations preserved the increase in resistance behaviour near the high impedance boundary. This highly accurate simulation framework allows us a mechanism for optimizing sensor geometry without costly experimental evaluation.