When performing plastic surgery, precision is of the utmost importance. Whether you are doing a delicate rhinoplasty, a challenging reconstructive hand surgery, or craniofacial surgery, the instruments matter. Standard sets of instruments might be acceptable for a general surgical procedure, but a custom surgical kit based on a specialty in plastic surgery was exponentially faster, safer, and more efficient.

Creating a plastic surgery set is about more than just quality – it is about choosing important instruments that fit your method, patient requirements, and surgical subspecialty. This guide will show you how to create a custom plastic surgery set for your own practice, whether it’s focused on cosmetic, reconstructive, hand, or craniofacial surgery.

Why Custom Plastic Surgery Sets are Important in Plastic Surgery

Plastic surgery is different than many surgical fields in that it requires a higher level of craftsmanship. Each procedure is unique; even slight variations in instrument size, tip design, or ergonomics can change the outcomes of the case. Customizing your plastic surgery set offers:

• Greater accuracy according to your operative style.
• More efficient workflow containing only the instruments you require—nothing added.
• Less downtime using familiar and high-quality instruments.
• Consistency between cases and familiarity within the team regarding the setup.

Step 1: Determine Your Area of Specialty

Before running off and choosing instruments, clearly establish the types of plastic surgery you mostly perform. Each subspecialty has different considerations and needs for instruments:

1. Cosmetic Surgery

Cosmetic procedures are performed with aesthetic intent (e.g., facelift, breast augmentation, rhinoplasty, liposuction, blepharoplasty) and involve delicate and fine-pointed instruments that minimize trauma to the tissues and optimize fine aesthetic outcomes.

Some examples include:

• Fine dissecting scissors and forceps
• Liposuction cannulas
• Skin hooks and retractors
• Fine needle holders for suturing
• Facial rasps, elevators and mallets for rhinoplasty

2. Reconstructive Surgery

Reconstructive surgery involves a cosmetic procedure, such as breast reconstruction after mastectomy, skin grafts, or scar revision, but it needs to rebuild structures and deep tissues. Reconstructive surgery will require a combination of delicate and heavier instruments.

Some examples include:

• Skin graft knives and dermatomes
• Tissue forceps and trauma clamps
• Micro and macro tissue scissors
• Suture tying boards and calipers for symmetry
• Hemostats for vascular control

3. Hand Surgery

There are implications for the ergonomic position and scale of the instrument:

• Incisional scissors and needle holders
• Fine nerve hooks and vessel dilators
• Bone rongeurs and small bone saws
• Kirschner wire instruments
• Zipper suture and tendon repair kits

4. Craniofacial Surgery

Craniofacial procedures, particularly for congenital anomalies and trauma, cover a range of instruments from strong to fine, particularly those involved in bone manipulation, tissue elevation, and microsurgery.

• Periosteal elevators and malleable retractors
• Cranial burrs, saws, and fixation systems
• Raspators and chisels for bone shapes
• Microsurgical forceps during vascular anastomosis
• Suturing systems and plating systems on facial bones

Step 2: Select Instrument Categories

Most surgical sets will have the following categories, regardless of group. Once a category is determined, modifications can be made within each category for performance and comfort.

1. Scalpels and Knives

• Select blade sizes and shapes based on the type of incision (e.g., #11 for sharp puncture, #15 for small facial cuts).
• Consider disposables or reusables, a choice of preference.

2. Scissors

• Straight or curved scissors can be used for dissection or trenching tissue.
• Supercut or tungsten carbide blades are available for longevity.

3. Forceps

• Adson, DeBakey, or Brown forceps will depend on the type of tissue to grasp.
• Toothed or non-toothed will depend on use (i.e., atraumatic/displace vs. grip).

4. Needle Holders

• Microsurgical needle holding instruments with fine jaws are for craniofacial or hand surgery, sutures, etc.
• Standard Mayo-Hegar or Crile-Wood types are for general suturing.

5. Retractors

• Small retractors like Senn or Ragnell retractors may be used in cosmetic or hand surgery. Malleable or self-retaining retractors like Weitlaner retractors would be used for deeper structures.

6. Elevators and Dissectors

• Sharp elevators are used for skin and blunt elevators are used for periosteal dissection. If the elevator is longer, long-handled elevators are appropriate and widely used in craniofacial or reconstructive work.

7. Specialty Instruments

• There are a variety of cannulas for liposuction with a range of diameters and tip configurations. Skin graft meshers or dermatomes, are often part of the reconstructive kit. Bone saws, rongeurs, and chisels can be found in craniofacial kits.

Step 3: Consider ergonomics and surgeon preference

Ergonomics will have major influences on both surgeon burnout and accuracy. When selecting instruments for the kit, look for instruments that are:

• Lightweight to reduce hand fatigue.
• Ergonomically designed to provide greater support and control for the microsurgeon.
• Balanced to provide adequate feedback in the hand.

The effect of surgeon preference, however, should also be considered. For example, when several enter and make kits for all surgeons involved, let them have their choice of instrument brand or style or at the least indicate their preferences.

Step 4: Materials and Quality of Manufacturing

A custom set is an investment for the long haul so the materials used can extend the life of the instruments, ease maintenance, and provide a more sterile environment.

Materials of interest:

• German stainless steel: Very durable and excellent corrosion resistance.
• Titanium: Very light and non-magnetic. Good for microsurgery.
• Tungsten carbide inserts: Extend the life of scissors and needle holders.

Evaluate surface finish—matte or satin finishes reduce glare in the OR, which is beneficial in ultra-detailed work.

Step 5: Sterilization and Tray Configuration

A unique configuration should be created while considering sterilization and speed of configuration.

• Utilize autoclavable trays with silicone instrument organizers for efficient sterilization and organization.
• Label each tray and/or container based on the type of procedure.
• Individualize micro-instruments in an EMP padded tray to avoid damaging the instruments!
• Evaluate color-coding your trays or modular trays that allow multi-specialty practices.

Step 6: Review and Finalize the Set

When ready to finalize your custom plastic surgery kit:

• Conduct mock setups in the OR to assess flow and coverage.
• Confirm instrument compatibility with other surgical systems or implants.
• Discuss your selection and layout with the surgical staff who work with you; they often see practical improvements.

Most manufacturers, including Hasni Surgical, assist in building custom surgery sets. If you approach the manufacturer with your needs, they can provide you with sample instruments along with accurate quotes, ensuring the set will work with your practice.

Partnering with the Right Manufacturer

When it comes to working with instrument manufacturers, you should be aware that not all manufacturers will provide the same level of quality or customization. When looking for a partner manufacturer, I recommend looking for a partner that:

• Specialized in reusable, surgical-grade instruments
• Has a wide catalog with plenty of customizable options
• Sells sterilization trays and custom labels
• Provides a warranty and after-sales support

Conclusion

The formation of a custom plastic surgery set is far more than logistics; it is a conscious decision on how the surgical impact affects success outcomes, efficiency, and patient satisfaction. By thoughtfully choosing instruments based on your surgical specialty, personal preferences, and workflow, you can create a kit that maximizes your surgical potential.

Plan, edit, and make your kit the best it can be; the right instruments will enhance your skills and allow them to be on show with each incision and suture.

At Hasni Surgical, we have partnered with many plastic surgeons since 1986 to provide high-performance, precision-made plastic surgery instruments.

From a basic set for facial cosmetic surgery to complex craniofacial reconstruction, we are working to ease your journey of finding a solution for you and your practice!