Porticos Designs Nuclear Medical Device

Radioactive medicines and dyes, which enable PET scanning and other modern diagnostic methods, are created by placing an organic substance in front of a particle accelerator and irradiating the substance. Then, this allows the person analyzing the data provided during this process to be able to properly view and identify what should or should not be brought to the attention of a medical professional or patient.

A local inventor and entrepreneur came to Porticos, a product design and product development engineering consulting firm in Morrisville, NC with the prototype of an “Accelerator Target” which would allow fast and economical production of a radioactive medical dye. The client asked us to optimize the size and function of the prototype while simplifying the manufacture and assembly processes.

Nuclear Medical Device diagram 2

In addition to accomplishing these tasks, Porticos’s hardware design engineers were able to create a separate “fill station” to support the device. Our engineers also helped the client establish a supply chain appropriate to the scale and schedule of the project. The production of this accelerator target allows for a much quicker process altogether, and the efficiency of having a fill station nearby to support the device makes it available for use for longer periods of time. Additionally, this technology supports PET scanning and modern diagnostic methods alike, so this also opens a window for technology to evolve in such a way that makes the use of the accelerator target more of a necessity and less of an option or alternative to what is already being used.

The product is now used in the United States and Europe, and Porticos hopes this product will continue to reach those who need it most in the medical field, as it saves time, money, resources, and is a fast, safe, and efficient way to render more timely results. Our hardware engineers remain committed to bring new, innovative products to the market, making the lives of businesses and customers simpler and better in quality.

Nuclear Medical Device diagram 3

Porticos Produces Rugged Pistol Grip

Porticos, a product design and product development engineering consulting firm in Morrisville, NC, continues to revolutionize in the world of hardware engineering and innovative technology development. One of Porticos’ most innovative projects to date is their involvement in the development of a rugged pistol grip.

Symbol Technologies, an American manufacturer and worldwide supplier of mobile data capture and delivery equipment, headquartered in Holtsville, NY, is currently a subsidiary of Zebra Technologies (Lincolnshire, IL). When Symbol Technologies came to Porticos’ hardware engineers, the pistol grip accessory proved to be an engineering and concept modeling challenge. It was a challenge Porticos was excited to meet and execute, as well as a project that remained in line with Porticos’ area of expertise.

Mechanical Concept Design

In order to most effectively create the ergonomic geometry required for the rugged pistol grip, a high-proficiency pro engineer was necessary. From an engineering perspective, it was essential for the pistol grip to pass the rugged testing that Symbol Technologies’ products have a reputation for.

In addition to the necessity to pass a ruggedness test, the interface to the main unit had to simple yet secure, while also accommodating the large number of critical interfaces. Porticos’ hardware engineers provided all of the mechanical design concept and executed the development of this product, all the way up to the successful transition to the production manufacturing source.

Porticos is proud to be part of such an innovative, essential project, and continues to shrive to create forward-thinking technology that will make as much of a mark in 40 years as it does today.

Symbol Technologies was ultimately satisfied with the concept design and execution of the rugged pistol grip, and it is currently being used in today’s market. Porticos’ hardware engineers was happy to collaborate with Symbol Technologies and offer up their expertise to ensure the production of the product was what would best suit consumers and the company overall.

Porticos Engineers Rugged Laptop

Dell, a popular developer of computers and other innovative technology, wanted to develop a ruggedized variant of a product from their laptop computer line. They turned to Porticos, a product design and product development engineering consulting firm in Morrisville, NC, for their expertise in this area.

Latitude ATG Development Challenges

The Latitude ATG is a tough, All-Terrain Grade laptop designed for industries like construction, manufacturing, oil and gas, as well as public organizations such as police forces. Built and tested to meet MIL-STD 810F—a tough military standard of durability—the Latitude ATG is designed to meet almost any physical challenge and the most demanding work environments.

Porticos’ hardware design engineers have ample experience designing products to meet the MIL-810F requirements and a history of supporting Dell on other projects, and was honored to design the ATG.

The two most challenging aspects of the ATG project were isolation of the hard drive and display, and designing the hinge and latch systems to accommodate the new design. What made the hard drive even more difficult a task was the need for it to fit into the same space currently allocated in the non-ATG D620 Latitude platform. The solution was to take a physically smaller Hitachi hard drive, and design a protective case that would function as the interface to the existing electrical connections. This also effectively protected the hard drive from shock and vibration.

The hard drive with it’s mated rigid flex was secured in a frame molded from EAR Specialty C8002 isolation material, then sandwiched between two sheets of 3M “G Sheet.” To meet the thickness limitations while still addressing stiffness goals, a titanium stamping was mated to a magnesium casting to form the mechanical enclosure. Similar isolation solutions were chosen to support the display.

After modeling the hinge mechanism and latches in Pro-Engineer, Porticos’ hardware engineers conducted finite element analysis (FEA) using the COSMOS analysis tool. The design was optimized to address high-stress areas, and the results were shared with the manufacturing source.

In addition to the structural analysis conducted, Failure Mode Effect and Analysis (FMEA) and Design For Assembly (DFA) were conducted. The feedback was then incorporated into the final Pro-E 3D CAD geometry and drawings.

With its shock-mounted, removable hard drive, shock-mounted LCD screen, a dust and spill-resistant keyboard, port covers and highly durable, textured paint to protect against scratches, scuffs and daily wear, the Latitude ATG is prepared for life working in the field.

Porticos Develops RFID Reader

Porticos, a product design and product development engineering consulting firm in Morrisville, NC, has developed many products for the Sirit—currently owned by 3M—portfolio. The RFID reader unit displayed is a good example of the type of products Porticos’ hardware engineers are not only capable of conceptualizing, but producing.

Product Design Concept

The harsh industrial environment in which items such as RFID readers can be developed require IP protection. To ensure IP protection, effectively securing the safety of consumers in the future, Porticos’ hardware engineers prioritized the ability to test the RFID reader in a safe environment. They worked hard allow space in their process for trial and error, while not sacrificing the security of the project overall.

The electronic functionality requires complete RF isolation from the outside world, as well as between the digital and RF sections inside of the unit. The high-power output for the transmitter required creative thermal management solutions. During the design concept process, Porticos kept in mind the need to execute all requirements while not jeopardizing the cost, time spent in production, or build quality.

Their solution was to integrate 3 separate sections—RF, Digital and Power Supply—within the enclosure design. Porticos’s hardware engineer team conducted a thermal analysis to determine the most efficient means of handling the heat dissipation without requiring force cooling, otherwise known as fans. The resulting housings were die cast aluminum, with secondary operations for the cosmetics and critical sealing surfaces. These housings were manufactured by Porticos’ partner Funfiek.

The final product passed all radiated emissions and thermal tests with no issues. This resulted in the implementation of the reader into products on the market today. RFID readers are quickly becoming the most necessary piece of technology that many companies are looking to integrate into their products.

Porticos is proud to have worked diligently on such an essential, innovative piece of technology that is essential for the future.

Porticos Delivers Needle-Free Vaccines

BD Technologies and Innovation, who create next-generation technologies in Durham, NC, developed a needle-free vaccine delivery system as part of a grant supported by the Grand Challenges in Global Health initiative. To be viable in small villages within developing countries—which, more times than not, is where the greatest need lies—the system cannot require the use of refrigeration or electricity of any sort and it must be simple to administer by minimally-trained personnel.

Also, the system must be effective on children, ages 1-4—who are not capable of cooperation—or adults, and must be effectively kept safe from spreading disease, which can be done easily by not allowing re-use. Finally, the system must be relatively compact for shipping, it cannot require any special means of disposal, and, most importantly of all, it must have a cost-per-unit dose equal to, or, less than, existing injection methods. This posed as a grand challenge for hardware engineers.

BD Technologies turned to Porticos, a product design and product development engineering consulting firm in Morrisville, NC, for innovative product engineering to help its team develop the delivery system that could be tested in Phase I clinical trials. Porticos’ hardware engineering team provided new thinking and insight to discover simple solutions that were easy to prototype for laboratory testing, ultimately helping BD extend its intellectual property based on the Solovent platform.

The process Porticos took to get to this point was keeping in mind the core needs of BD while emphasizing the need for fast, flawless production, accuracy in the findings of the testing process, and continuing to elevate the need for simplicity.

The approach Porticos ultimately pursued was aerosolizing a dose of powdered vaccine for inhalation, using a simple device constructed of basic yet effective materials. BD utilized its Solovent unit’s dry dose powder inhaler (DPI) platform to aerosolize the powder, and needed a means of containing the cloud of vaccine, while simultaneously providing an interface for effective delivery to patients.

Because of the efficiency of Porticos’ engineers and the concept design behind the entire process, BD Technologies was able to effectively execute their desire for a needle-free vaccine delivery system, and it is cost-effective, not dependent on electricity, and able to be administered by even the most inexperienced personnel.

Porticos Helps Create Mail Insertion System

Porticos, a product design and product development engineering consulting firm in Morrisville, NC, partnered with technology and service innovators, Bell & Howell on the creation of The Ascender 16. The Ascender 16 is a mail insertion system that can insert a variety of shades of sizes as it pertains to mail and packages. Porticos’ hardware engineers collaborated on the development of the 4920 Format Turn Module for the Ascender 16 system itself.

This module makes the changeover process more efficient and accurate. The system’s changeover from a letter mail job to a flat mail job used to require time and a knowledgeable system operator, but this module reduces changeover need, and the amount of time needed to ensure the safe and reliable insertion of mail.

Module Hardware Design Specifications

The 4920 Format Turn Module contains a feed-through mode—or a “no turn” mode—which feeds unfolded and folded material with dimensions from 3″ to 12″ in length, and up to 0.25″ in width, or thickness. The module itself fits inside the Ascender system in the place of a previously used module, but adds no increase in size while also providing all the functions of the old module in addition to the format change capability that the module brings forward.

Porticos’ hardware engineers produced a software to accompany the module that is reconfigurable to either feed material straight through, or rotate flat stock material 90 degrees. The module is able to handle up to 1/4″ of materials that are 8.5 x 11 or A4, and turns 10,000 cycles per hour.

Concept Design Highlights

Porticos’ hardware design engineers originally faced some surface speed variations between belts and rollers, which posed as a challenge to consistent feeding. However, carefully tuning pulley sizes during prototype testing resulted in smooth operation.

Attention to all inertias and motor capabilities were important in the design concept. To accomplish the turn, the system is required to decelerate each packet from a transport speed of 150 inches per second, to a full stop. From there, it rotates 90 degrees then accelerates back to 150 inches per second. All of this occurs in about 1/4 of a second. Porticos was able to forsee the frictional characteristics and the durability of the rollers that accomplish the format changes were critical for proper operation. This then gave Porticos the foresight to carefully select materials, specialized coatings, and roller configuration. Overall, this led to a design that could precisely accomplish rotating the material 90 degrees while enduring long-term testing.

Porticos worked with Bell & Howell to develop the original, state-of-the-art Solix™ Mail Tray Loader, which handles up to 30,000 envelopes per hour. The revolutionary Ascender 16 system now has a module that enhances one of its more difficult processes, thanks to teamwork, innovation, and experience within Porticos’ hardware engineering team and concept design expertise.

Porticos Creates Small HD 500 Series On-Camera Monitor

Porticos, a product design and product development engineering consulting firm in Morrisville, NC, created yet another innovative, essential device—a 5-inch, full high-definition on-camera monitor. This on-camera monitor has a brilliant display, desirable form factor, and is easy to transport. Porticos’ hardware engineers’ goal was to design a durable, minimal, small-sized yet visually appealing, HD monitor that would be easy and reliable to manufacture and assemble.

Product Design Challenges Overcome

The concept design for the on-camera monitor required no major changes to the existing printed circuit board (PCB). This means that Porticos’ hardware engineers were able to create a design that reinforced the delicate HD display to improve robustness in both manufacturing and the end-use of the product. Porticos also created the design to shock-mount the display for improved product durability while simplifying product assembly. This ensures that in both transport and use, the on-camera monitor stays in place, and consumers can use without wondering if the device will go flying off their camera at any point in time.

The innovative monitor was created with an extremely durable chassis design, compatible for manufacture by machining or die casting, and its battery contacts is integrated into the rear cover. While there is a requirement added to integrate an infrared transceiver for remote control after the initial mechanical design was completed, it was done in such a way that it did not add to the size of the overall product.

Porticos’ hardware engineers created designs for mini-joysticks and placed external buttons in minimal space that are still easy to access and press, as well as an overall clean-looking design for use with or without a user-replaceable screen protector. However, this product was designed to be durable enough to work well without a screen protector, which can largely be attributed to the shock-mounting of the product to the camera itself. To maximize the small amount of space given, a hinged SD card access door was created and is located on the device in a manner that did not compromise the look of the exterior appearance.

Concept Design Highlights

Due to the demand for an on-camera monitor, the customer was able to utilize the same mechanical design for their 700 series monitors—which contains a larger screen—by scaling it up, reducing both the cost of development, and the time it takes to market. Additionally, the larger monitor size was able to sustain the same build chassis as the 500 series monitors which provided it with the same stability and durability.

Porticos Designs High-Impact Shield Mount for Construction Equipment

Porticos, a product design and product development engineering consulting firm in Morrisville, NC. This project is an example of Porticos’ design and engineering expertise, crafting solutions for heavy industrial machinery and other heavy equipment.

For the operation of large construction equipment, such as an excavator or backhoe operator, shields are undeniably crucial and necessary to execute the operation of said machinery effectively. During the hammering operation at quarries and in mining sites, shields protect operators from debris, and keep them moving forward steadily on difficult terrain.

With so many different cab models, it can be extremely difficult to focus on suggesting a certain type of shield while respecting industry specifications. This is due to the variety in cab frames, the sizes of the cabs, and what those who are handling the machinery hope to gain from a shield. The geometry and curvature of the cab’s glass also has to be considered, along with the location and availability of bosses.

Many frame designs require a unique attachment strategy for each cab style—because of the variety in location, depth and the number of bosses welded onto a cab’s frame. This leads to distinct and obvious issues with parts, training, installation, cost, and more.

Porticos’ hardware engineering team sought to create shield mounts that could both be strong enough to protect operators, and flexible enough to accommodate multiple cab models. This innovative concept design required attention to the industrial standard, and an awareness of the mechanisms used to make the cabs themselves function above all else.

To solve this unique product design challenge for this particular heavy industrial machinery, Porticos worked with many industry partners. From there, Porticos’ hardware engineering team developed a distinctive mount—a combination of brackets with slotted holes, universal ball joints and threaded rods that enabled the shield to mount to the frame of any cab without any issues.

Through this process, Porticos was able to find the perfect solution to reduce the number of unique parts needed for the installation of a sheila, and make a modular kit that is flexible enough to accommodate the majority of the varied cab model styles.

Porticos Develops Automated Medication Dispenser

Porticos, a product design and product development engineering consulting firm in Morrisville, NC, and Porticos Asia, the Hong Kong team which leverages Asian manufacturing for US and European clients, collaborated on a concept design that ensures accurate and consistent medication dosing for those concerned for their loved ones.

This smart, connected health hub dispenses the right pills at the right time of day. Since patients and pharmacists don’t have to sort or count pills with this devices, the dangers of human error are drastically reduced. Plus, the device can send reminder alerts to patients and connected them to trained pharmacists who can answer questions and give them advice.

Finally, patients and their loved ones can feel confident that medications are being taken properly, at the correct time, consistently with this wireless device that could fit easily into any home. Those who have been ridden with concern for their loved one on multiple medications are finally afforded some peace of mind with this life-changing device!

Detail Design: Balancing Precision and Ease

One of the fundamental pieces of the platform solution is to provide the medicine to the patient in a format that the device can properly dispense. For this innovative machine, that means a cartridge containing prepackaged foils of medicine. To meet this need, Porticos developed and designed “The Spooler.” The Spooler allows the pharmacist to efficiently and reliably package the patient-specific foils into cartridges that can then be put into the unit for dispensing by the patient.

Developing a product with such a high-stakes role in patient health presented several challenges. First, the Porticos product design team needed The Spooler to be agile and dependable—small enough to fit on a countertop, fast enough to produce a medication pack every 30 seconds, and reliable enough to be a life-or-death part of a healthcare plan. It also needed ethernet capability, and an easy-to-navigate touch screen, so even the least tech-savvy patient could use it with ease.

As the name suggests, The Spoolers’ main function is to wind and unwind the foil packets of medication to fill the cartridge. One of the obstacles faced by performing that function while meeting the time requirements is for the medication packs to jam or be torn by the mechanisms during that process. To overcome this obstacle, Porticos’ hardware engineers developed a variety of unique mechanisms, and performed designs of experiments to prove out the concepts. As a result, Porticos was able to create a Spooler that winds and unwinds smoothly every time—a reliable solution for the most critical part of patient care for this device.

One of the key steps that Porticos advised all customers to consider as part of the design process, is to prototype the design to allow functional evaluation before proceeding to production manufacturing. Case-in-point—an obstacle that was identified during initial prototype functional trails, specifically engagement and disengagement, was the Spooler’s “arm.” The arm interfaces with a hub in the cartridge to perform the winding function. Originally, Porticos’ hardware engineers designed a traditional latching mechanism to secure the arm in place, but soon realized that optimizing the process necessary to ensure good engagement with the cartridge hub, and the need for the pharmacists to easily disengage the arm was problematic. To solve this challenge, the team of hardware engineers devised a unique magnetic solution that not only met the functionality requirements, but exceeded the life cycle requirements as well.

As further testament to Porticos’ innovative contribution to the Spooler and overall product, Porticos’ engineers were named as inventor on multiple patents.

Hardware Production Challenge: Balancing Cost and Medical Standards

Once the Spooler was designed, a cost-competitive production plan that could also meet the high-quality standards for medical equipment was needed. Porticos Asia, the hardware production services arm of Porticos US, was able to identify the perfect production spot for a custom build—one that could match quality and cost efficiency with an aggressive delivery schedule. Ultimately, they were able to ship the first batch of Spoolers just twelve weeks after the start of production—all the while analyzing the manufacturing flow for further cost reduction in future production runs.

For more examples of how Porticos is Product Design for the Way We’re Designed, visit porticos-us.com.

Sleek New Design for Paper Product Dispensers

A new sleek, streamlined, and consistent look for paper product dispensers were designed and developed by Porticos engineers for the Von Drehle Corporation. The Porticos engineers were on board from concept through installation in customer locations.

Listening to their customers, the Von Drehle Corporation knew it was time to redesign and update the look of their paper product dispensers. They looked to the system engineers at Porticos who worked through multiple design requirements to fit various sizes and dimensions of products that could potentially be used in the new dispensers.

Product Design and Development Services

From initial ID sketches and requirements definition, prototype design and functional prototype testing, and all the way through to working with customer specified suppliers, Porticos met design challenges and tight deadlines to achieve an efficient, reliable, and attractive final product.

New Product Design for Paper Product Dispensers

The new designs have an improved locking mechanism for ease-of-use and high capacity towel and tissue capabilities which lessens the burden on maintenance staff.

Porticos product design example - Von Drehle tissue dispenser
New TranscendTM model. The twin jumbo dispenser is considered a controlled-use dispenser. It can only be used with von Drehle tissue to reduce waste, maintenance demands and costs, and holds almost 2,300 feet of soft 2-ply tissue.

White and a stainless finish are new color options in addition to the traditional black.

As an example of new product to the line is the Center Pull Towel Dispenser. This dispenser limits waste and cost by dispensing one towel at a time. This design also keeps the dispenser germ free and there will be never be a need to replace batteries. This design is perfect for kitchens, restrooms, food service areas, and anywhere a center pull towel dispenser works best.

For more information about this project, check out the case study here: Paper Product Dispensers Get a New Modern Look.