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Redesigned a 3D tool used for surgery planning

Redesigned a 3D tool used for surgery planning

Redesigned a 3D tool used for surgery planning

This product sits at the intersection of healthcare, AI, & software design, designed as part of a larger digital ecosystem.

This product sits at the intersection of healthcare, AI, & software design, designed as part of a larger digital ecosystem.

This product sits at the intersection of healthcare, AI, & software design, designed as part of a larger digital ecosystem.

Team

Team

UX Designer (Myself)

Sr. UX Designer

1 Product Manager

1 Product owner

3 Frontend Developers

3 Backend Developers

UX Designer (Myself)

Sr. UX Designer

1 Product Manager

1 Product owner

3 Frontend Developers

3 Backend Developers

Role

Role

Research

Conceptualisation

Design

Prototyping

Usability testing

Dev hand-off

Research

Conceptualisation

Design

Prototyping

Usability testing

Dev hand-off

Timeline

4months,2025

Client

Client

Leader in Dental Healthcare Europe and America

Leader in Dental Healthcare Europe and America

Designed for

Designed for

Medical Software

B2B and B2C platform

Medical Software

B2B and B2C platform

Timeline

4 months, 2025

* Client specific details are concealed or substituted with placeholders due to NDA *

* Client specific details are concealed or substituted with placeholders due to NDA *

Overview

Overview

Redesigned an AI-powered 3D tool that supports planning for surgeries by using 3D imaging, editing tools, clinical rules, and practitioner expertise.


Goal: Help dentists plan safer and more predictable surgeries. From a product POV– to give dentists the right level of editing tools, simplify the interface, and optimize collaboration while accounting for real clinical workflows & regulations.

Redesigned an AI-powered 3D tool that supports planning for surgeries by using 3D imaging, editing tools, clinical rules, and practitioner expertise.


Goal: Help dentists plan safer and more predictable surgeries. From a product POV– to give dentists the right level of editing tools, simplify the interface, and optimize collaboration while accounting for real clinical workflows & regulations.

What is digital planning in dental surgery 🦷 💻 ?

What is digital planning in dental surgery 🦷 💻 ?

In digital planning, the dentist takes 3D scans of the patient’s mouth and uses 3D software to safely plan the position of the tooth, implant, and implant placement guide - avoiding damage to nearby teeth, roots, and nerves.

In digital planning, the dentist takes 3D scans of the patient’s mouth and uses 3D software to safely plan the position of the tooth, implant, and implant placement guide - avoiding damage to nearby teeth, roots, and nerves.

Importance of 3D Planning in Surgery 🥼🚨

Importance of 3D Planning in Surgery 🥼🚨

We visited clinics to see how 3D planning translates into real surgeries, helping anchor design decisions in surgical constraints & time-critical workflows.

We visited clinics to see how 3D planning translates into real surgeries, helping anchor design decisions in surgical constraints & time-critical workflows.

Surgical decisions rely heavily on planning

Surgical decisions rely heavily on planning

Virtual plans directly define how surgery will take place, with very little room for change.

Virtual plans directly define how surgery will take place, with very little room for change.

The cost of planning errors is high on surgery

The cost of planning errors is high on surgery

Any errors in planning can cascade into real-world patient health risks

Any errors in planning can cascade into real-world patient health risks

The better the plan, the smoother the surgery

The better the plan, the smoother the surgery

Good 3D planning makes surgery faster, safer, and more predictable.

Good 3D planning makes surgery faster, safer, and more predictable.

As a result, dentists are forced to select one of the two devils

a. Outsource planning to Labs
(Adds days & cost)


🗓️ 💰


Delegating planning to labs turned a 30minute surgery into a 4-day, back-and-forth lab workflow + the cost.

b. Do it themselves (Eats into personal time and ruins work-life balance)


😣 ⏰


Dentists who have the skill & equipment end up spending late evenings and weekends wrestling outdated software.

So, what is the problem exactly?

So, what is the problem exactly?

75% of a dentist's time goes into digital planning on 3D softwares & only 25% on the surgery. This is due to outdated, complex “do-everything” legacy tools.


Even the basic tools are poorly designed, overcomplicated and slow. With caseloads reaching 300- 800+ annually, small inefficiencies become massive bottlenecks

75% of a dentist's time goes into digital planning on 3D software & only 25% on the surgery. This is due to outdated, complex “do-everything” legacy tools.


Even the basic tools are poorly designed, overcomplicated and slow. With caseloads reaching 300- 800+ annually, small inefficiencies become massive bottlenecks

75% of a dentist's time goes into digital planning on 3D softwares & only 25% on the surgery. This is due to outdated, complex “do-everything” legacy tools.


Even the basic tools are poorly designed, overcomplicated and slow. With caseloads reaching 300- 800+ annually, small inefficiencies become massive bottlenecks

But.. the client had a half-baked solution 🚧 for this

But.. the client had a half-baked solution 🚧 for this

Implant Copilot - an AI-powered 3D tool 🏗️

It automated time-staking steps, eliminated the outdated features, & simplified the UI.

150

Understanding the problem in detail

After auditing Implant Copilot and interviewing 14 users from Slovenia, Portugal, India, the Netherlands, and the US, along with clinic and lab visits in India, we found users were still dissatisfied.

After auditing Implant Copilot and interviewing 14 users from Slovenia, Portugal, India, the Netherlands, and the US, along with clinic and lab visits in India, we found users were still dissatisfied.

Why did users still struggle even with a simpler UI and faster AI-generated results?

AI can assist; but not decide

AI can assist; but not decide

AI delivers results in 10 minutes, but limited editing tools force dentists into complex software, reintroducing the same slow, frustrating workflow.

AI delivers results in 10 minutes, but limited editing tools force dentists into complex software, reintroducing the same slow, frustrating workflow.

UX issues exist, but

Regulation isn’t a suggestion

and Business isn’t an option

UX issues exist, but

Regulation isn’t a suggestion

and Business isn’t an option

We uncovered multiple usability issues; however, in healthcare, every design decision comes with legal baggage. Solutions had to align with legal, business & product vision.

We uncovered multiple usability issues; however, in healthcare, every design decision comes with legal baggage. Solutions had to align with legal, business & product vision.

UX Issues:

UX Issues:

  1. Limited editing capabilities

  1. Limited editing capabilities

  1. No onboarding for new experiences

  1. No onboarding for new experiences

  1. Tedious sharing & exporting flows

  1. Tedious sharing & exporting flows

  1. Non-intuitive components

  1. Non-intuitive components

Legal Considerations:

Legal Considerations:

  1. AI errors must be clearly visible

  1. AI errors must be clearly visible

  1. User is the final decision maker

  1. User is the final decision maker

Business Goals:

Business Goals:

  1. Product scalability & long-term growth

  1. Product scalability & long-term growth

Redesign approach :

Design for simplicity in a legacy-heavy space and make the system easier to understand - without taking agency away from the user.

Design for simplicity in a legacy-heavy space and make the system easier to understand - without taking agency away from the user.

Smallest-Screen First Approach

Smallest-Screen First Approach

Designed the software for 1280 × 720px to keep the 3D workspace usable and smoothly scale to larger screens.

Designed the software for 1280 × 720px to keep the 3D workspace usable and smoothly scale to larger screens.

Smallest-Screen First Approach

Designed the software for 1280 × 720px to keep the 3D workspace usable and smoothly scale to larger screens.

Collapsable sidebars for Maximising

3D Workspace

Collapsable sidebars for Maximising 3D Workspace

Collapsable sidebars for Maximising 3D Workspace

Sidebar stepper auto-collapses to maximise 3D space during non-interactive periods.

Sidebar stepper auto-collapses to maximise 3D space during non-interactive periods.

Introduced Layers to Replace the Limiting Tooth Chart

Introduced Layers to Replace the Limiting Tooth Chart

Future Scalability: The layers system easily allows new components to be introduced in the future helping with product and business vision

Future Scalability: The layers system easily allows new components to be introduced in the future helping with product and business vision

Rules for Layer and 3D interactions

From unscalable tabs to scalable layers and editing system


Contextual Edit Box: Appears only when a component is selected, reducing clutter and showing details solely when needed.


Partial Editing: The edit box uses partial editability (editable implant fields vs. uneditable sleeve details) to ensure data consistency

From unscalable tabs to scalable layers and editing system


Contextual Edit Box: Appears only when a component is selected, reducing clutter and showing details solely when needed.


Partial Editing: The edit box uses partial editability (editable implant fields vs. uneditable sleeve details) to ensure data consistency

Old design

Old design

Teaching a new user a new interaction & defining the feature logic

Instead of manually entering implant angles & heights, a slow, error-prone method used in competitor tools

Quick Align lets users instantly match the angle/height of two components using

and clicking align button on the top of layers panel

Since this shortcut introduces a new user behavior, it requires intentional placement and onboarding.

SHIFT

+

Left click

Designing 3D and 2D Interactions for Implant Guide editing

Designing 3D and 2D Interactions for Implant Guide editing

🪟 What Are Inspection Windows?

🪟 What Are Inspection Windows?

Inspection windows are small openings on the implant guide 3D model that let dentists visually confirm if the guide is fully seated, requiring precise placement during digital planning. Hence, how the windows will be interacted with, not only in the 2D left panel but also in the 3D editor, needed to be defined.

Inspection windows are small openings on the implant guide 3D model that let dentists visually confirm if the guide is fully seated, requiring precise placement during digital planning. Hence, how the windows will be interacted with, not only in the 2D left panel but also in the 3D editor, needed to be defined.

Figma make ✨

Figma make ✨

Prototype of 3D behaviours for dev teams

Prototype of 3D behaviours for dev teams

Developed beta version 🧑🏻‍💻

Developed beta version 🧑🏻‍💻

Beta version focused on validating the technical feasibility

Beta version focused on validating the technical feasibility

The beta revealed several issues:

  1. the darkened centre area reduced visibility

  1. the cylinder window's colours lacked contrast on darker surfaces.

  1. The diameter/height controls weren’t clear enough.

Iterations

  1. Diameter and height are editable directly in 3D using intuitive handles

  1. Brighter green with white outlines improved visibility

  1. The cylinder’s lower half is transparent for visibility

Finalised design

A more interconnected ecosystem

The fixed "Send to" button connects users directly to other internal tools and products of the client.

A more interconnected ecosystem

The fixed "Send to" button connects users directly to other internal tools and products of the client.

Balancing Legal Requirements and User Experience

Balancing Legal Requirements and User Experience

Optional tools were tucked under 'More tools' to keep the workflow fast. But some new users seemed to overlook them.

Optional tools were tucked under 'More tools' to keep the workflow fast. But some new users seemed to overlook them.

Impact

50-70%

faster case planning.
Reduced planning time from 60–90 minutes down to 30–45 minutes per case.

Tested

Usability testing with 7 users showed significantly reduced confusion during critical decision-making moments, with participants completing key tasks smoothly and confidently.

2× faster

Next steps..

Design and development of the core features are complete, and the product is currently undergoing FDA and MDR approval. To support the highest level of medical certification, we are collecting rigorous evidence that users can understand and use the software independently, which is a necessity for FDA approvals of the highest grade approvals. For these, we had to conduct moderated interviews, usability testing, and detailed documentation, all of which are submitted as part of the regulatory review.

The product is in beta version and we are waiting for FDA approval.

Design and development of the core features are complete, and the product is currently undergoing FDA and MDR approval. To support the highest level of medical certification, we are collecting rigorous evidence that users can understand and use the software independently, which is a necessity for FDA approvals of the highest grade approvals. For these, we had to conduct moderated interviews, hands-off usability testing, and detailed documentation, all of which are submitted as part of the regulatory review.

The product is in beta version, and we are awaiting FDA approval.

My takeaways from this project..

Mirroring the physical world on screen

The importance of deeply understanding how digital tools map to real-world workflows.


Designing within strict regulatory constraints
FDA and MDR Class III (high risk) approvals are slow and highly regulated, and Premarket Approval (PMA) requires rigorous clinical evidence. Features need to be intentionally simple for initial approval while still being designed with future scalability.


Early and continuous developer collaboration

With complex 3D interactions, clarity comes from building and testing—rapid prototyping and early feasibility checks work better than waiting for perfect designs.


Designing systems, not just screens
This project reinforced that complex tools require clearly defined interaction rules and states. Thoughtful system logic makes advanced workflows feel predictable and learnable.


In healthcare, good design is rarely about perfect solutions.

It's about making trade-offs visible, reducing risk incrementally, and knowing when not to change something yet.


Learning PRD collaboration
As the team was relatively new to cross-functional collaboration with a design team, I learnt to write product and feature requirement documents, often consolidating inputs and aligning with PMs, POs, and design leads to support smoother design collaboration.