Client: Michael Meyer from Pittsford Volunteer Ambulance

Guide: Mark Minunni

Sponsor: Jeff Benck


  • Nikki VanOstrand (Biomedical Engineer) - Project Manager
  • Nicole Hachmann (Biomedical Engineer) - Communications
  • John Arnold (Electrical Engineer) - System Engineer
  • Kevin Lee (Biomedical Engineer) - System Engineer
  • Emelia Paulisczak (Industrial and Systems Engineer) - Purchaser
  • Lorna Burdick (Biomedical Engineer) - Facilitator

Project Overview: 

The EZ-IO insertion device is a small battery-powered drill for intraosseous infusion. The device has three needle sizes and is used on both adult and pediatric patients. The current device sometimes runs out of battery and does not have enough power to drill all the way into the bone to deliver fluids and/or other medications. A handheld device testing unit that could measure if the battery of the EZ-IO has the power and torque generation required to complete needle insertion is desired by the client.

The goal of this project is to build a working prototype of the testing unit that will accurately and reliably measure if the driver has the power needed to complete the needle insertion before the device is used on a patient. The amount of power needed to complete the needle insertion will be determined as well. A SOP will be written showing the how the amount of power needed to complete the insertion was obtained and a preliminary production and marketing plan will be developed. The device needs to be handheld and have a display on the testing unit be based on gradient of LED's. The unit is powered by a 9V battery.


Our solution is a battery-powered 3D printed device that easily fits in the hand.

The design of the device is established as a handheld unit, in which one can insert the EZ-IO into a 3D printed pentagon bit. Once inserted, the EZ-IO is turned on, and the power of the torque is collected from the rotating bit by the RPM sensor and Adafruit Board. The recorded sensor data is run through the code on the Adafruit and used to light up the correct LED of the five available corresponding to the result output by the code.

The power board receives power directly from a nine volt battery, down converts to five volts, and distributes it to the other components as seen below in A. The main power board contains the magnetic sensor for reading the RPM and output LED’s to show the desired output. Both of these components communicate through the Adafruit board to give us the result as seen in B.

A: Electrical power diagram of the device.

B: Recorded data is converted and transferred to the LEDs.

The farthest right green light (LED 5) means the EZ-IO can insert the needle easily, the second green light (LED 4) means the EZ-IO can be inserted with a small amount of effort, the farthest right yellow light (LED 3) means the needle can be inserted with moderate effort (and therefore a new drill should be ordered soon), the second yellow light (LED 2) means the needle can be inserted with a lot of effort (and a new drill should be ordered immediately), and the one red light (LED 1) means the drill will not succeed in inserting the needle.


The 5 LEDs are arranged as shown in the table. There are two green LEDs on the right side (LED 4 and LED 5), two yellow LEDs in the middle (LED 2 and LED 3), and one red LED on the left side (LED 1). Each LED lights up corresponding to the level of power of the EZ-IO drill.

The design of the device is elongated as seen below and is 5.85 inches long by 3.1 inches wide by 1 inch tall. The device is 3D printed with PBS plastic, which was proven to be very durable by test dropping the device, as well as resistant to all cleaning chemicals used by medical professionals.

The device is divided into a top and bottom part, which is held together by two screws at the top of the device. The device was designed that way so it could be opened if the battery needs to be replaced or the code needs to be modified. The top part includes five 0.22 inch holes for the LED lights, which are flush with the top of the casing and the sides, leaving no significant gaps. Another hole can be observed at the top of the casing, which is designed to hold the 3D printed pentagon bit in a semi-frictionless manner. The bottom of the casing includes a casing to hold the battery, two extrusions that hold the screws in place, and four holes to be able to attach the electrical components to it.

Images of the device.

Engineering requirements with the target value, acceptable value and actual result.

Technical Aspects:

Imagine RIT Video

Technical Paper


Standard Operating Procedure (SOP)

Manufacturing Plan

Lightning Talk Video

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