Matthew Kuhn

Supported manufacturing process improvements to reduce financial scrap for the Powered Echelon Platform of devices, resulting in annual savings of over $100k. Led design verification/validation and implementation of component design changes for the family of Endopath Articulating Linear Cutters to reduce product inquiries (PIs) and adverse events (AEs). Generated 12 published innovations and 10 pending patents.

Contributed to design solution activities through the utilization of CAD tools, simulation tools, fundamental engineering principles, and expertise offered/conveyed from seasoned Team Engineers.

Specializations: Design for Six Sigma (DfSS), Statistics, Design for Manufacturability and Assembly, Component Material Analysis, and Manufacturing Processes.

Implemented DfSS and reliability engineering techniques to optimize robust design of clinical chemistry systems and immunoassay systems. Designed experiments to evaluate prototype subsystem performance. Improved design of reagent mixing instruments and subsystems.

Additional Accomplishments:
Designed experiments to test new prototypes and created design verification protocols.
Led design changes to reagent mixing instrumentation to reduce vibration by 75% and operating temperature by 15%.
Implemented design changes to photometer instrumentation, saving $100,000 a year in manufacturing costs.
Optimized design and software of patient sample barcode reading system and reduced read errors by 50%.

Served as the University of Delaware's Student Representative to communicate the goals, activities, and concerns of the Newark community to Dow Electronic Materials stakeholders.

The Dow Community Council aims to communicate the safety, health, environmental and emergency preparedness to fence-line neighbors, emergency responders, and other community members. Our goals included developing and maintaining effective, open and frank lines of communication between Dow and CAC stakeholders.

Improved the design and performance of medical devices and laboratory diagnostic equipment by utilizing Design for Six Sigma techniques. Specialized in the optimization of robotic motion control profiles and motion error analysis. Efforts resulted in lower failure rates of various prototype subsystems, improved equipment reliability, and a reduction in the frequency of costly service visits for in-field equipment.

Additional Accomplishments:
Managed interactions with DfSS consultants and project members to facilitate team communication and achieve project milestones.
Led weekly meetings to assure timely completion of project milestones and maintained communication between different departments.
Optimized subsystem design for maximum reliability under different environmental conditions.
Excelled in experiment design, 3D modeling in SolidWorks, fixture design, and team leadership.

Developed medical device products and provided hands-on support for testing prototype devices, components, and materials. Designed and built ISO-certified cleanroom for prototype testing.

Additional Accomplishments:
-Designed and wired building-wide nitrogen gas/compressed air delivery system.
-Created and submitted official FDA documented device testing/experimental testing reports.
-Designed, programmed, and implemented custom tank pressure monitoring/datalogging system. System allowed for the simultaneous wireless monitoring of six separate nitrogen tanks.

The eighth summit of the Engineering Change Lab was held at the Texas Medical Center Innovation Institute and focused on exploring the future of engineering through the lens of biomedical engineering and innovation in healthcare. Matthew Kuhn, Project Leader and Design Engineer at the Johnson & Johnson Center for Device Innovation (CDI), described CDI’s process for developing transformative medical devices.

A method for removing a tissue lesion where an anchor is established with the lesion. A channel is created in the tissue leading to the anchored lesion. A tissue core is created which includes the lesion. The tissue core is ligated, amputated and removed from the channel.

The present invention is directed to systems, devices and methods for trans-septally delivering carbon dioxide through a minimally invasive catheter to create a gaseous pocket or emphysema between the posterior wall of the left atrium and the esophagus during cardiac ablation of the left atrium. This pocket of gas expanded tissue serves to thermally insulate and separate the esophagus from the left atrium during ablation to prevent esophageal damage and the formation of an atrial-esophageal fistula. The system comprises a control system to precisely deliver the gas to a desired location through a needle-based catheter assembly.

A method for adjusting the operation of a clip applier using machine learning in a surgical suite is disclosed. The method comprises gathering data during surgical procedures, wherein the surgical procedures include the use of a clip applier comprising a crimping drive configured to be mechanically advanced through a crimping stroke. The method further comprises analyzing the gathered data to determine an appropriate operational adjustment of the clip applier and adjusting the operation of the clip applier to improve the operation of the clip applier.

The present invention is directed to systems, devices and methods for trans-septally delivering carbon dioxide through a minimally invasive catheter to create a gaseous pocket or emphysema between the posterior wall of the left atrium and the esophagus during cardiac ablation of the left atrium. This pocket of gas expanded tissue serves to thermally insulate and separate the esophagus from the left atrium during ablation to prevent the formation of an atrial-esophageal fistula. The system comprises a control system to precisely deliver the gas to a desired location through a needle-based catheter assembly.

Surgical clip appliers are disclosed comprising a plurality of clips which are stored in a compressed state. When a stored clip is moved into the crimping chamber of the surgical clip applier, the clip can assume a configuration which is different than its stored configuration before it is crimped.

Current articulating clip appliers have no way or feeding clips to the end effector through the articulation joint. This results in the articulation joint having to be proximal to the stored clips, which lengthens the region being articulated. A mobile clip feeder assembly eliminates the need to store clips distal from the dual-plane joint.

Current articulating clip appliers have no way of feeding clips to the end effector through the articulation joint. This results in the articulation joint having to be proximal to the stored clips, which lengthens the region being articulated.

An ultrasonic surgical instrument and method of assembly with a predetermined alignment includes first and second modular assemblies and an electrical lockout. The first modular assembly includes at least a portion of an end effector configured to manipulate a tissue. The second modular assembly includes a transducer power circuit and an activation switch electrically connected to the transducer power circuit. The electrical lockout is electrically connected to the transducer power circuit and configured to inhibit the activation switch from powering the ultrasonic transducer with the first and second modular assemblies misaligned from the predetermined alignment such that the first and second modular assemblies are in a locked-out state. The electrical lockout is further configured to allow the activation switch to power the ultrasonic transducer with the first and second modular assemblies in the predetermined alignment such that the first and second modular assemblies are in an operational state.

An ultrasonic surgical instrument that includes an ultrasonic transducer, a handle assembly supporting the ultrasonic transducer, a clamp arm assembly, and a mechanical lockout assembly. The handle assembly includes a housing and an ultrasonic blade acoustically coupled with the ultrasonic transducer. The clamp arm assembly includes a clamp arm. The mechanical lockout assembly is configured to switch between at least an unlocked configuration and a locked configuration. In the locked configuration, the handle assembly and the clamp arm assembly are not completely coupled together and the operator is physically prevented from activating the instrument using an operator input feature. In the unlocked configuration, the clamp arm assembly and the shaft assembly are completely coupled together and the operator is able to activate the instrument using the operator input feature.

An ultrasonic surgical instrument that includes a handle assembly including at least one user input feature; an ultrasonic transducer supported by the handle assembly, a shaft assembly configured to removably couple with the handle assembly, and a mechanical lockout assembly. The shaft assembly includes a distal end portion. The shaft assembly further includes an end effector extending distally from the distal end portion, and an ultrasonic waveguide configured to be acoustically coupled with the ultrasonic transducer. The mechanical lockout assembly is configured to move between at least an unlocked configuration and a locked configuration. In the locked configuration, the handle assembly and the shaft assembly are only partially coupled together physically preventing the user from activating the instrument using the user input feature. In the unlocked configuration, the handle assembly and shaft assembly are completely coupled together enabling the user to activate the instrument using the user input feature.

An ultrasonic surgical instrument includes a first modular assembly including at least one operator input feature an ultrasonic transducer supported by the first modular assembly, and a second modular assembly configured to be removably coupled with the first modular assembly. The second modular assembly includes at least a portion of an end effector extending distally from a distal end portion of the second modular assembly. The instrument includes a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration. In the locked configuration, the first modular assembly and the second modular assembly are partially coupled together such that the operator is physically prevented from activating the instrument using the operator input feature. In the unlocked configuration, the first modular assembly and the second modular assembly are completely coupled together and the operator is able to activate the instrument using the operator input feature.

An end effector for a surgical clip applier includes an elongate body, a clip forming system positioned within the body and arranged to receive an unformed surgical clip, and an actuation mechanism operatively coupled to the clip forming system to actuate the clip forming system and thereby bend the unformed surgical clip into a tissue-ready surgical clip. First and second jaw members are positioned at a distal end of the body and arranged to receive the tissue-ready surgical clip for crimping.

An end effector for a surgical clip applier includes an elongate body, a clip revolver rotatably positioned within the body and providing an inner bore that defines a plurality of clip slots angularly spaced from each other about an inner surface of the inner bore, wherein a plurality of surgical clips are receivable within the plurality of clip slots in a nested helical array. First and second jaw members extend past a distal end of the body and aligned to receive a distal-most surgical clip of the plurality of surgical clips, wherein the clip revolver is rotatable to sequentially align each surgical clip with the first and second jaw members.

A surgical clip applier includes a drive housing, an elongate shaft that extends distally from the drive housing, an end effector arranged at a distal end of the elongate shaft and including first and second jaw members, and an articulation joint interposing the end effector and the elongate shaft. The articulation joint includes a flexible shaft length articulable in a plane of motion and having a first end and a second end, a lumen defined within the flexible shaft length and extending between the first and second ends, and a clip track provided within the lumen and extending at least partially between the first and second ends to guide surgical clips through the articulation joint.

Current articulating clip appliers store clips proximal to the end effector and distal to the articulation joint, which lengthens the region being articulated. Packing clips more efficiently in the distal region of an articulation joint could reduce the articulating length of a clip applier. This can be achieved through a system of vertically stacked clips with a passively driven, screw-fed advancement mechanism.

Current articulating clip appliers have no way or feeding clips to the end effector through the articulation joint. This results in the articulation joint having to be proximal to the stored clips, which lengthens the region being articulated. A mobile clip feeder assembly eliminates the need to store clips distal from the dual-plane joint.

Current articulating clip appliers store clips proximal to the end effector and distal to the articulation joint, which lengthens the region being articulated. Packing clips more efficiently in the distal region of an articulation joint could reduce the articulating length of a clip applier. This can be achieved through a system of vertically stacked clips contained in an interchangeable cartridge unit.

Cerebral palsy (CP) is a non-progressive brain disorder that impairs the control and movement of the body. CP is caused by damage to the motor neuron areas in the brain, which may be congenital or acquired after birth, and is why development of CP occurs in developing infants. People who suffer from CP experience slower walking speeds due to their aberrant gait cycle. Since plantar flexion and dorsiflexion are critical to the gait cycle, any level of involuntary muscle spasticity would increase the difficulty of maintaining a proper gait cycle. Likewise, Magnetic Resonance Imaging (MRI) is a useful method for evaluating motor function, blood flow, and tissue morphology. This technology can be used to more precisely measure and monitor muscle activity. Having the ability to combine a dynamometer (a device that can be used to measure the force, torque, and power of various anatomical joints) and MRI treatment can prove to be one of the most effective ways to measure muscle spasticity treatment. However, previous attempts to use a dynamometer have only produced data for active isometric plantar flexion, which could not be calibrated to tried-and-tested methods. Many dynamometers are not MRI compatible because they lack the geometry to fit into a MRI bore or they contain magnetic materials. The goal of this study is to compare isometric PF and DF strength and to determine if there is a change in peak strength at the isolated ankle when seated with legs fully extended compared to lying supine. Additionally, this study hopes to determine the repeatability of the subjects after brief period of time in the supine position which will be used in an MRI to conduct future research endeavors. Results will be used and impact design decisions for an MRI capable device.

A two-­leg squatting exercise is a body resistance exercise that is commonly applied in sports, recreation, and everyday activity. The two-­leg squat targets the quadriceps, hamstrings, and gluteal muscle groups. These muscle groups include the vastus lateralis, semitendinosus, and gluteus maximus. Performing a proper squat requires the user to stand with their feet shoulder-­width apart and toes pointed forward. The user then descends into a bending of the hips, knees, and ankles until the knees reach parallel (90 degree angle). During descension, the user's back should be straight, abdominal muscles tight, and knees centered over feet. Common improper squatting techniques include: staggered feet position, rounding the lower back, knees pointed inward, and lifting heels off the ground. The goal of this study is to determine whether proper biomechanical squatting form can be induced using dynamic feedback from simple force plates.

Over the past few years there has been there has been a surge of the production of large volume, highly viscous drugs that are used to treat patients with chronic illnesses. West Pharmaceutical Services is a manufacturer of the SmartDose® auto-injector; an automatic drug delivery device. The device is capable of injecting drugs with high viscosities and large volumes, and it features a unique cartridge that is pre-filled with a drug before it is inserted into the auto-injector. The goal of this project was to develop a filling process or a device that will be used in a clinical setting to fill these cartridges, thus eliminating the need for the implementation of a costly manufacturing supply chain. Most importantly, the device needs to comply with FDA sterility requirements, therefore a set of metrics was created to evaluate the device’s performance. These metrics are: accuracy, user failure rate, transfer time, user friendliness, variable fill volume and variable fluid viscosity. Through a concept selection phase and multiple design iterations a final prototype was developed and built. It features a custom control system for variable volume filling, an LCD screen with input buttons, a locking mechanism to secure the components during the transfer process and an aluminum housing. The prototype was tested by performing multiple drug transfers from a standard drug vial to the SmartDose® cartridge using water and glycerine solutions to mimic drugs of various viscosities. Other students were also used to perform transfers to gather feedback on the user friendliness of the device. Overall, the prototype performed extremely well and it passed every metric with slight variability at the high end range of viscosity and transfer volume.

As part of a course on Microfluidics, our team created an educational outreach module and lesson plan designed to explain an important micro/nano-scale fluidic phenomena, electro-osmosis. In hopes that we could spark an interest in complex microscale fluid mechanics in young children, we constructed a hands-on demo that intuitively describes electro-osmosis that a teacher can use in front of a high school or middle school class. Included with our demo: • Low-cost construction plans that enable teachers with minimal or no budgets for additional educational materials to build and use our module in the classroom. • A demo summary sheet that details step-by step usage of it. • A technical note for the teacher that provides in depth knowledge of the phenomena and the relevant chemistry and fluid/electro-mechanics. Why and how it works; How Engineers use this phenomena (or overcome it); and Current Applications/Uses. • A compiled list of additional resources for teachers and/or students to do additional reading on the topic. This can include things like YouTube video etc, in addition to web and or print resources. • Supplemental instructional materials targets at two different grade levels (7-8th grade and 10-12th grade) that are used by the teacher to teach this concept to the class

There are millions of individuals in the United States alone that are affected by osteoarthritis. However, many Americans have access to modern healthcare which helps assure that most people receive adequate treatment for their osteoarthritis. Unfortunately, this is not the case in developing countries. There are similar rates of osteoarthritis outside of the US. In these areas, treatment for osteoarthritis, a total knee arthroplasty (TKA), needs to be performed by well-trained surgeons and medical technicians. These skilled individuals are often in short supply, therefore the WOGO team has made it their mission to provide TKA services to women in less economically stable areas. However, TKA surgical tooling kits require costly transportation, long sterilization processes, and have difficulty with inventory management. The goal of this design project is to modify the existing toolkit in order to reduce shipping costs by reducing the size and weight of the toolkits, and to improve toolkit inventory management. The proposed design consists of a reorganized tool tray layout, changing the material of a majority of the toolkit from surgical steel to UHMWPE, and eliminating unnecessary tools. The redesigned tray will reduce the size of the toolkit by approximately 33%. Using tools made of UHMWPE instead of surgical steel will greatly reduce the weight of the TKA toolkit. Redesigning one of the tools, specifically the finishing guide, will eliminate the need for one of the pin clamps without compromising the function of the finishing guide. These designs will meet the goal of the project without negatively affecting the TKA surgical procedure. After extensive design development, two prototypes were constructed and tested to evaluate their performance within the constraints of several design metrics.

Brain-machine interfaces have great potential for the development of neuroprosthetic applications to assist patients suffering from brain injury or neurodegenerative disease.Theses devices work by connecting the brain and its associated electrical activities with computers and other electronics. A BMI can conceptually separated into 3 distinct parts. There is a sensor to record the electrical signals from the brain, a signal processor of neural signals to decode intended movement, and an effector to carry out the action, such as a robotic limb. Every year, thousands of veterans return home with missing limbs and debilitating injuries. Thousands more individuals suffer from the loss of movement of limbs through spinal cord injuries or neurologic disorders. Neuroprosthetics and brain-interfacing machines have the potential to assist these patients. However, there are several factors inhibiting progression of neuroprostetic technology, including a lack of bidirectional feedback between the BMI and the patient, heavy computer processors, and severe immobility. Our objective is to provide innovative solutions to many of these issues in order to advance the clinical benefits of neuroprosthetics for those with motor deficiencies.

Major Depressive Disorder (MDD) is a mental disorder characterized by a persistent low mood, low self-esteem and a loss of interest in normally enjoyed activities. It is estimated that one in ten U.S. Adults will report having suffered from depression at some point in their life.These disturbances to daily life result in over $83 billion/year in lost workplace productivity. Depression, a major socioeconomic burden, is also linked to 60% of suicides occurring annually in the United States. There is no cure for depression; treatment involves a combination of psychotherapy and medication. Selective-serotonin reuptake inhibitors (SSRIs) are the most commonly prescribed antidepressants medication and function by blocking serotonin reuptake into the cell, increasing activity in the synapse to overcome decreased overall levels. When SSRIs are taken orally, they enter the bloodstream and bind to a serotonin transporters. There is currently no way to stop SSRIs from binding to transporters found in the GI tract, blood cell platelets, and various parts of the brain, which can lead to several undesired side effects including sexual dysfunction, weight gain, abnormal sleeping patterns, hyperextension, nausea, and increased bone fracture. We propose a targeted delivery system for SSRI’s to the limbic system, the area of the brain most implicated in depression, in order to reduce the side effects of SSRI treatment. Targeted delivery will require the carrier system to address four key issues: (1) biocompatibility, (2) directed movement, (3) crossing the blood brain barrier and (4) binding affinity. This novel carrier will be a liposome; bio-compatible, and, when coated with a layer of polyethylene glycol (PEG), will have a relatively long in vivo lifetime.