Design of an ultrasound‐emitting drill guide for freehand pedicle screw navigation

Accurate pedicle screw placement in spinal surgery is critical as inaccuracies can lead to morbidity and suboptimal outcomes. Navigation and robotics have reduced malplacement rates, but their adoption is limited by high costs, learning curves, surgical time, and radiation. The authors propose an ultrasound-emitting and self-localising drill guide for precise screw placement that overcomes the limitations of current techniques.The preliminary configuration analysis involves systematically varying design parameters and assessing localization performance using lumbar spine MRI based simulations. The authors evaluate localization techniques based on accuracy and optimization capture range.Results suggest that feasible designs can accurately estimate position. A promising design features a 5 mm radius cannula with ten 35mm-long ultrasound strips, 32 elements per strip, and a fanned-out emission profile. A multi-start active-set optimization algorithm with six initial estimates ensures reliable and efficient localization.The simulation suggests that the proposed design can achieve sufficient localization accuracy for pedicle screw navigation. These findings will guide the fabrication of a novel ultrasound-emitting drill guide for further evaluation and physical testing.