A method for image-guided positioning of cochlear specimens in insertion test benches using 3D printed stands

Abstract

Abstract Cochlear implants include an electrode array (EA) which needs to be inserted into the cochlea. Insertion tests using artificial cochlear models (ACM) or ex vivo specimens are widely used methods during EA development to characterize EA design properties, including insertion forces. Measured forces are directly linked to the orientation of the cochlear lumen with respect to the insertion axis of the test bench. While desired insertion directions in ACM experiments can be predefined by design, specimens are individually shaped and the cochlear lumen is embedded invisibly. Therefore, a new method for accurate, individual specimen positioning is required. A key element of the proposed method is a customizable pose setting adapter (PSA) used to adjust the specimen’s fine positioning. After rigid fixation of the specimen to a holder featuring spherical registration markers and subsequent cone beam computed tomography the desired insertion direction is planned. The planned data is used to calculate the individual shape of the PSA. Finally, the PSA is 3D printed and mounted between force sensor and specimen holder to correctly align the specimen to the test bench’s insertion axis. All necessary hard- and software have been developed including the specimen holder, a software for registration and trajectory planning, and a custom Matlab script whose output drives a parametric CAD file of the PSA. Positioning accuracy was determined in a first trial using 10 virtual trajectories and was found to be 0.23 ± 0.12 mm and 0.38 ± 0.17°. The presented stereotactic positioning procedure enables high repeatability in future ex vivo insertion experiments due to accurate, image-guided control of the insertion direction.