Electron Microscopy and Elemental Analysis of Defective Drysdale Nucleus Manipulator Instruments Implicated in Surgical Complications

•Reusable Drysdale manipulators are widely used in cataract surgery.•Damage or residues can accumulate with instrument reuse.•Scanning electron microscopy found sharp defects in all (5 of 5) reused instruments.•Defects had elemental composition mainly of carbon or aluminum.•Sharp defects may contribute to complications including posterior capsule rupture. To analyze microtopography of 5 reusable Drysdale nucleus manipulator (DNM) paddled tips for sharp defects and evaluate their elemental composition to determine probable source, investigating 2 instruments (DNM 1 and 4) implicated in causing posterior capsule rupture (PCR) and 3 instruments with sharp edges identified by finger-tip interrogation intraoperatively. Experimental laboratory investigation. DNM paddled tips were analyzed using scanning electron microscopy (SEM) to evaluate for sharp surface defects (number, dimensions), and subsequently energy dispersive x-ray spectroscopy (EDS) performed on sharp defects to determine their elemental composition. All reused DNMs analyzed (5 of 5) had significant structural defects on SEM analysis including sharp burrs, cavities and indentations, surface debris or residues, and roughening, compared to the new instrument (DNM 3, control) which had no defects. DNM 1 had 2 sharp defects, a larger 14 × 76-µm one and a craterlike 167 × 220-µm defect containing debris. EDS found that DNM 2 had 3 of 4 burrs composed mainly of carbon, the fourth of mixed composition (calcium, sulfur, oxygen); DNM 4 had 1 small burr, EDS significant for carbon; DNM 5 had 3 prominent burrs, the largest of 20 × 28 µm, 2 composed of aluminum, and some carbon residue. DNM 6 had 1 burr composed of aluminum and 3 prominent cavity defects, the largest covering 781 µm2. Reusable DNMs are widely used in cataract surgery. Sharp carbon- or aluminum-containing burrs were detected on all reused instruments analyzed together with 1 burr of mixed composition, originating from (1) organic residues, (2) instrument fragments, or (3) salt and contaminant deposits. Sharp defects may contribute to capsular damage including PCR, and residues may pose other safety concerns. Therefore, we support development of a quality, reliable single-use alternative instrument and further encourage careful inspection of all reusable instruments principally by finger-tip interrogation for sharp edges preuse.