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A health care professional (hcp) reported via a distributor that at the most beginning of a functional endoscopic sinus surgery (fess) procedure, the doctor noticed that the blade vibrated abnormally.The doctor reinstalled the blade but still could not resolve the problem.Then, the doctor used another new blade to complete the procedure.The second blade could function properly without vibration with the same power system.It was the initial use of the blade.The procedure was delayed for about 5 minutes.No error code was displayed on the console.There was no patient impact.
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Analysis found that the inner blade would spin freely by hand.There was no damage to the tip.Visually, the inner shaft was bent just distal to the inner hub which would have resulted in the reported event.When viewed under magnification, there was damage to the hubs that is consistent with improper of difficulty loading the blade into the handpiece: deformation on the front hub prior to the locking area caused by a misalignment of the handpiece locking mechanism; locking area deformation caused by the back side of the front collet of the handpiece; and deformation of the proximal inner hub chevrons caused by the handpiece drive mechanism.Shear or bending forces while loading may bend the shaft.There were no loose components.Even with the deformation of the hubs, functionally, the device loaded securely into a handpiece, ran at 3,000 rpm in oscillate mode/direction, and vibrated as reported.A review of the xpi did not indicate any evidence to point to improper manufacturing and there are checks for damage throughout the process.A bur or blade that is not properly loaded would result improper engagement with the suction seal, drive, and locking mechanism of the handpiece.If information is provided in the future, a supplemental report will be issued.
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