Computer and robot assistance in craniotomy/craniectomy procedures is intended to increase precision and efficiency of the removal of calvarial tumours, enabling the preoperative design and manufacturing of the corresponding implant. In the framework of the CRANIO project, an active robotic system was developed to automate the milling processes based on a predefined resection planning. This approach allows for a very efficient milling process, but lacks feedback of the intra-operative process to the surgeon. To better integrate the surgeon into the process, a new teleoperated synergistic architecture was designed. This enables the surgeon to realize changes during the procedure and use their human cognitive capabilities. The preoperative planning information is used as guidance for the user interacting with the system through a master—slave architecture. In this article, the CRANIO system is presented together with this new synergistic approach. Experiments have been performed to evaluate the accuracy of the system in active and synergistic modes for the bone milling procedure. The laboratory studies showed the general feasibility of the new concept for the selected medical procedure and determined the accuracy of the system. Although the integration of the surgeon partially reduces the efficiency of the milling process compared with a purely active (automatic) milling, it provides more feedback and flexibility to the user during the intra-operative procedure. Editor's note: This paper was commissioned for this Image Guided Surgery special issue, but has been published in an earlier issue. It can be found in Proc. IMechE, Part H: J. Engineering in Medicine, 2010, 224(H3), 441–452. DOI: 10.1243/09544119JEIM596.

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Trepanation of the skull is a common procedure in craniofacial and neurosurgical interventions, allowing access to the innermost cranial structures. Despite a careful advancement, injury of the dura mater represents a frequent complication during these cranial openings. The technology of computer-assisted surgery offers different support systems such as navigated tools and surgical robots. This article presents a novel technical approach toward an image- and sensor-based synergistic control of the cutting depth of a manually guided soft-tissue-preserving saw. Feasibility studies in a laboratory setup modeling relevant skull tissue parameters demonstrate that errors due to computed tomography or magnetic resonance image segmentation and registration, optical tracking, and mechanical tolerances of up to 2.5 mm, imminent to many computer-assisted surgery systems, can be compensated for by the cutting tool characteristics without damaging the dura. In conclusion, the feasibility of a computer-controlled trepanation system providing a safer and efficient trepanation has been demonstrated. Injuries of the dura mater can be avoided, and the bone cutting gap can be reduced to 0.5 mm with potential benefits for the reintegration of the bone flap.

One of the most common procedures in neurosurgery is the trepanation of the skull. In this paper, a synergistically controlled handheld tool for trepanation is introduced. This instrument is envisioned to reduce problems of dural tears and wide cutting gaps by combining a soft tissue preserving saw with an automatic regulation of the cutting depth. Since usability and safety of the semi-automatic handheld device are of utmost importance, the complex interaction between the user and the system has been analyzed extensively. Based on prospective usability evaluation the user interaction design and the corresponding user-interface were developed. The compliance with the relevant factors effectiveness, efficiency, error tolerance, learnability and user satisfaction was measured in user-centered experiments to evaluate the usability of the semiautomatic trepanation system. The results confirm the user interaction design of the semiautomatic trepanation system and the corresponding safety strategy. The system seems to integrate itself smoothly into the existing workflow and keeps the surgeon aware of the process.