Lightweight Medical Device Housing: Enhanced Performance Through Innovation

The Challenge

Our client needed to reduce the weight of their portable medical device housing while maintaining impact resistance and meeting strict FDA requirements. The existing design was causing user fatigue and had occasional failures during drop testing.

• Required 20% weight reduction target
• Needed to maintain or improve impact resistance
• Must meet FDA and ISO 10993 requirements
• Cost reduction goals for high-volume production

Our Approach

We employed a comprehensive approach combining advanced materials science, structural analysis, and innovative design techniques:

• Conducted extensive FEA simulations for optimization
• Evaluated multiple material options through testing
• Used topology optimization for weight reduction
• Implemented Design for Manufacturing (DFM) principles

The Solution

Our solution incorporated several innovative features:

• Optimized rib structure for maximum strength-to-weight ratio
• Custom PC/ABS blend with enhanced impact properties
• Integrated mounting features to reduce assembly time
• Textured surfaces for improved grip and aesthetics

Results & Impact

The new design exceeded all project objectives and received overwhelmingly positive feedback from end users. Key achievements included:

• 22% reduction in overall weight
• 45% improvement in impact resistance
• 18% reduction in manufacturing costs
• Zero field failures reported since launch
• Successful FDA and ISO 10993 certification

"ATI Engineers' innovative approach to our device housing redesign exceeded our expectations. The significant weight reduction and improved durability have received outstanding feedback from our medical staff users."