Award Winning Surgical Device Design | Dragonfly, Laparoscopic Instrument

Surgical devices need to feel like a natural extension of the surgeon using them, particularly during long procedures where control and confidence can directly influence performance.

That philosophy sits behind Dragonfly, the laparoscopic vessel sealer recently recognised with a prestigious Red Dot Best of the Best Design Award. The project demonstrates how human factors, industrial design, engineering and applied science can come together to solve practical challenges faced every day in the operating theatre.

Designing Beyond Function

Laparoscopic instruments are often used for hours at a time, making ergonomics and weight distribution an important part of overall device performance. Dragonfly was developed to bring together technical capability with a user centred design approach, helping improve comfort and control without compromising functionality.

Usability from the Beginning

Understanding how surgeons naturally interact with handheld devices shaped the project from the earliest concepts.

Using our dedicated surgical human factors facilities at our UK Crux Technology Centre, the team evaluated how balance, weight distribution, actuation force and grip influenced comfort over time. Rapid prototyping enabled multiple design iterations, allowing subtle refinements to surface geometry, control placement and handling characteristics before progressing further.

Applying Design Craft

The Dragonfly device explored multiple design language directions alongside complementary colour and material finishes (CMF). Inspiration came from industries where tactile feedback are critical, including gaming technology, where responsiveness control are fundamental to the user experience.

Grip geometry, surface transitions and material selection were refined to create a device that provides immediate feedback while remaining comfortable throughout extended procedures.

The result is a cordless laparoscopic instrument that feels balanced in the hand and accommodates a wide range of hand sizes and operating styles through adjustable features.

Bringing Disciplines Together

Dragonfly reflects the strength of multidisciplinary development. Human factors specialists, industrial designers, engineers and applied scientists  worked together throughout the project, ensuring usability and technical performance evolved in parallel.

That collaborative approach ultimately led to international recognition with a Red Dot Best of the Best Design Award.  If you’re developing the next generation of surgical devices, we’d love to discuss how our expertise can help bring your ideas to life. Get in touch here via projects@cruxproductdesign.com.