A 3D stereo camera system for minimally invasive brain surgery — engineered to operate in the most demanding environment in medicine.
Design a miniaturized 3D camera system that fits within strict surgical access constraints, maintains sterile-field compatibility, and delivers high-resolution stereo imagery in real time — all within medical-grade certification requirements.
Full mechanical and optical design, system integration, DFM for small-batch production, and regulatory documentation support for CE marking under MDR.
Functional stereo camera assembly delivered through multiple prototype iterations. System integrated into BrainsGate's surgical platform and validated in clinical evaluation.
BrainsGate develops technology for minimally invasive neurosurgery. Their platform required a compact 3D imaging system that could be passed through a narrow access port into the surgical field, providing surgeons with stereoscopic depth perception in real time.
The engineering constraints were severe: the housing had to fit within a specific diameter envelope, survive sterilization cycles, and be optically aligned to submillimeter tolerances. The stereo baseline — the separation between the two optical axes — needed to be precisely controlled to deliver accurate depth perception at surgical working distances.
We worked through multiple design iterations, using FEA to optimize the housing for stiffness within the weight budget, and developed a custom alignment fixture to enable repeatable assembly at the required optical tolerances. The final design was validated through environmental testing and integrated into BrainsGate's clinical evaluation program.