Performance Testing of Huber Needles for Coring of Port Septa

The Food and Drug Administration received complaints of Huber needles creating cores in the septa of ports of gastric banding devices. One of these complaints represented a cluster of similar events, even though no deviations from design specifications or recommended practices were subsequently identified by the manufacturer. The authors conducted this comparative investigation of off-the-shelf Huber needles and ports from several manufacturers to determine if engineering parameters could be identified that could account for the coring complaints. Huber needles from ten manufacturers were evaluated for coring using intravascular access ports from five manufacturers. A detailed optical analysis was also performed to identify needle features that would possibly account for coring. The majority of the tested needles performed as they should, i.e., they perforated the port septa without creating cores. However, needles that did produce cores were found to have sharp edges at the heel edge of the needle lumen, the edge of the ground bevel opposite from the needle tip that opens to the inner surface of the cannula tube. Manufacturing processes, which dulled or rounded the sharp heel of the bevel after bevel grinding, prevented coring. As a result of this investigation one manufacturer voluntarily recalled their product and another manufacturer implemented coring testing as part of their quality control. To prevent coring needles from entering the market as a result of manufacturing flaws, optical inspection of the heel edge and coring testing should be performed as part of routine quality control.