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 ProtoCAM
has worked on many rapid prototyping projects where design for
manufacturability (DFM) was important to the project. ProtoCAM
has experience with rapid prototyping for handheld devices, small
electronic devices, medical devices, and aerospace prototyping,
but this project is the only project that combined all of these
aspects into one prototype.
Background
Charles River Laboratories worked with ProtoCAM to
quickly develop a handheld medical test device to be used for scientific
testing on NASA Space Shuttle flights. The device would be
used during space flights to perform microbiological tests on horseshoe
crabs. “"Charles River Laboratories provides research
models and laboratory animal support services, preclinical services,
and clinical services to the biomedical market" (from
the Charles River Laboratories website.) Charles
River Laboratories's Rapid Micro Products use their Endosafe™ technology
in multi-functional, point-of-use test systems (PTS), which they
call a “"lab-on-a-chip".
 Design for Manufacturability for this Hand Held Device
Charles
River Laboratories approached ProtoCAM with a very good preliminary
design for this test device and needed to get the instrument into
production quickly to meet NASA's timeline. ProtoCAM’s
engineers were able to use their vast experience with design for
manufacturability and DFM engineering to suggest a few design improvements
pertaining to the manufacturability of the device. Specifically
in this design, which was fit and functionally well done, ProtoCAM
suggested form improvements to the design, such as:
- Resizing and moving some of the ribs in the interior of the product
- Adjusting the angle of draft
- Increasing the wall thickness slightly to avoid sink indentations during molding
 The end result was a stronger piece that was easier and less costly to manufacture.
The device consisted of 4 plastic components
along with the printed circuit board and keypad. Using stereolithography, ProtoCAM created SI 50 SLA prototypes for testing with the electronic components. No RTV molds were needed. ProtoCAM
did the rapid tooling to move quickly into the injection molding
production process to produce about 2000 sets. The entire process
was completed in less than 5 weeks.
 Key Benefits of Working with ProtoCAM
- Fast turn-around
- Product engineering expertise in design for manufacturability, reducing costs and time to market while making the product work and look better
- Experience with handheld devices, electronic devices, and medical devices
- Design confidentiality (Permission was granted from Charles River Laboratories for this case study.)
Results
Charles River Laboratories' handheld medical test
device prototyping was completed within the project schedule and
was deployed into production in timely fashion. The Endosafe™
device was successfully used at NASA's Marshall Space Flight
Center and in NASA's space shuttle for microbiological testing
of horseshoe crabs.
Sources
Please visit the Rapid
Micro Products section of the Charles
River Laboratories website to learn more about their Endosafe™
devices.
Contact ProtoCAM for Design for Manufacturability and Rapid Prototyping for Handheld Devices
Please contact us to discuss your handheld prototype, to utilize our design for manufacturability expertise in your prototype, or to request a quotation.
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