Design of a Slender Tuned Ultrasonic Needle for Bone Penetration

This paper reports on an ultrasonic bone biopsy needle, particularly focusing on design guidelines applicable for any slender tuned ultrasonic device component. Ultrasonic surgical devices are routinely used to cut a range of biological tissues, such as bone. However the realisation of an ultrasonic bone biopsy needle is particularly challenging. This is due to the requirement to generate sufficient vibrational amplitude capable of penetrating mineralised tissue, while avoiding flexural vibrational responses, which are known to reduce the performance and reliability of slender ultrasonic devices. This investigation uses finite element analysis (FEA) to predict the vibrational behaviour of a resonant needle which has dimensions that match closely to an 8Gx4inch bone marrow biopsy needle. Features of the needle, including changes in material and repeated changes in diameter, have been included and systematically altered to demonstrate that the location of and geometry of these features can significantly affect the resonant frequency of bending and torsional modes of vibration while having a limited effect on the frequency and shape of the tuned longitudinal mode. Experimental modal analysis was used to identify the modal parameters of the selected needle design, validating the FEA model predictions of the longitudinal mode and the close flexural modes. This verifies that modal coupling can be avoided by judicious small geometry modifications. Finally, the tuned needle assembly was driven under typical operational excitation conditions to demonstrate that an ultrasonic biopsy needle can be designed to operate in a purely longitudinal motion.