Bioptigen Envisu Image System

Bioptigen, a technology leader in ophthalmology from Morrisville, North Carolina partnered with Porticos, a product design and product development engineering consulting firm in Morrisville, NC to create the Envisu, a state-of-the-art OCT (Optical Coherence Tomography). The Envisu is a system that produces detailed images of the internal structure of the eye for both clinical and research applications. 

Designers at Bioptigen needed to advance their product and they selected Porticos’s engineers for the design. Porticos optimized Envisu by utilizing the proprietary “engine,” while also mitigating annual production costs. 

Ultimately, Bioptigen considered a reduction in size & weight, with improved thermal performance and shock resistance. The designers also added the ability to disconnect specific components, which made the unit easier to build and service.

Porticos’ engineers partnered with multiple Bioptigen teams to identify the device’s most essential features, as well as areas that needed to be improved. Following multiple iterations of industrial design concepts and mockups, Porticos designed a new system that met all of the objectives.

This led to the creation of the probe interface module, which allowed interchanging the scanner probe in the base unit.  This module required adding a new connection point in the main optical fiber. The connection was executed with minimal signal loss and included a clever dust cover for the optical connection.

Separate optical and electronic modules were created, which were independently removable from the chassis for servicing.  This configuration assisted with assembly while a hinged electronics enclosure aided with debugging, allowing service personnel to access the interior while operating the unit.

A component layout was established to maximize thermal performance, and this was eventually coupled with the positive pressure fan cooling system. Hot swap hard disk drives were implanted, with custom shock mounts, rounding out the internals Bioptigen was looking for.

A unique optical fiber routing tray that accommodated an array of fiber lengths was fitted with size and weight distribution that, along with handholds in key locations, enabled disassembly of the unit to assist with portability during transport.

Porticos implemented lightweight and strong structural chassis, low-cost thermoformed covers, and removable spool to improve transportability, as well as adapted OEM medical cart to complete the system.

Overall, Porticos worked to improve product aesthetics and ergonomics, along with manufacturing methods compatible with a limited annual production volume and a simplified design. The engineers provided expertise with Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Service (DFS).

Collaboration on Medication Monitoring Device: Porticos and Porticos Asia

Porticos, a product design and product development engineering consulting firm in Morrisville, NC, and Porticos Asia, its manufacturing partner, recently collaborated on a medication monitoring device that helps patients and caregivers keep track of medications via a smartphone app.

The device can be attached to prescription pill bottles at the pharmacy, and it tracks the weight of the pills with a high-precision sensor to determine if they are being taken as directed. The device then communicates via Bluetooth to the patient’s smartphone app. Downloading the app brings the patient into the device eco-system, providing the patient with medication reminders and providing their caregivers with a complete record of their medication compliance.

Product Design and Manufacturing Partnership

Porticos worked directly with Porticos Asia to rapidly deliver 2,500+ units for user trials on a tight schedule, working throughout weekends and holidays to meet deadlines.

Headquartered in Hong Kong and working with suppliers in the Shenzhen region, Porticos Asia is in the advantageous position of being able to provide low cost, high quality production to customers who may otherwise not have access to such capabilities. The focus on production services will include part, sub-assembly and full production manufacturing, supply chain management, cost reduction, quality control and order processing.

Product Design Challenges

Porticos is proud to have been involved in the conceptual design and development of concept of operations and device feasibility, and was responsible for the definition of requirements, the research of available sensing technologies (capacitive, resistive, strain gauge, etc.), and the proof of concept performance testing of sensing technologies.

Porticos also designed and built a fixture to efficiently program and test PCBAs during inline assembly testing, and designed and built a fixture for end-of-line checkout of devices with initial device calibration.

Porticos is proud to have been chosen for this project. For more on Porticos’ engineering consulting services, click here for a services list.

Convenience at Your Fingertips: Porticos Helps Develop Automated Medication Dispenser

We’ve all been there: worried that a loved one isn’t taking his medications or, perhaps worse, is taking medication improperly. It can lead to hospital stays, the inability to live independently, and lots of stress on patients and loved ones.

Spencer Healthcare Solutions, an RTP-based company, has developed a hardware and software platform to address this medical challenge.

The “Spencer” is a smart, connected health hub that dispenses the right pills at the right time. Since patients and pharmacists don’t have to sort or count pills with Spencer, the danger of human error is drastically reduced. Plus, Spencer can send reminder alerts and even connect patients to Spencer-trained pharmacists for questions and advice.

So patients and their loved ones can feel confident that medications are taken properly and at the correct time. If you’ve ever worried about a loved one on multiple medications, you know peace of mind is life changing!

Porticos Design Challenge: 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 Spencer device can properly dispense. For the Spencer that means a cartridge containing prepackaged foils of medicine. To meet this need, Spencer Healthcare Solutions engaged Porticos to develop the “Spooler”. The Spooler allows the pharmacist to efficiently and reliably package the patient-specific foils into a cartridge that can then be put into the Spencer unit for dispensing by the patient.

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Creating a product with such a high-stakes role in patient health presented several challenges. First, the Porticos 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 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 to 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 engineers ideated a variety of unique mechanisms and performed design 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 a critical part of patient care.

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 manufacture. Case in point was an obstacle that was identified during initial prototype functional trails; specifically engagement and disengagement of the Spooler “arm”. The arm interfaces with a hub in the cartridge to perform the winding function. Originally, Porticos designed a traditional latching mechanism to secure the arm in place, but the team soon realized that optimizing (1) the forces necessary to ensure good engagement with the cartridge hub and (2) the need for the pharmacists to easily disengage the arm was problematic. To solve this challenge Porticos engineers devised a unique magnetic solution that not only meets the functionality requirements but exceeds the life cycle requirements as well.

As further testament to Porticos innovative contribution to the Spooler and Spencer products, Porticos engineers were named inventor on multiple patents.

“Porticos engineers did an excellent job of developing the spooler unit,” said Jeremy Bridges, Hardware Manager with Spencer Healthcare Solutions. “They worked very well with our team and were very responsive to our needs. We were especially impressed with some of the innovative solutions that they develop and were able to integrate into the product.”

Porticos Production Challenge: Balancing Cost and Medical Standards

Once the Spooler was designed, Spencer Healthcare Solutions needed a cost competitive production plan that could also meet the high-quality standards for medical equipment. Porticos Asia, the 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. 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.

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Meeting The Challenge: Another Product Design Partnership

Through both the development and production stages, Porticos US and Porticos Asia were proud to support Spencer Healthcare Solutions.

“We consider Porticos to be a valuable partner in reaching our company goals,” said Ben Wetzel, Finance Manager at Spencer Healthcare Solutions. “They have provided excellent engineering and manufacturing support. Furthermore they have remained flexible throughout our engagement to meet our changing needs.”

For more information on the product, visit www.helloimspencer.com.

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

Introducing Livi™—your new home healthcare aid!

The ground-breaking Livi™, Porticos’ latest engineering challenge, revolutionizes patient care and prescription management by dispensing medicines as prescribed—ensuring accuracy and precision for patients with complex pharmaceutical needs. In August 2014, Porticos announced that a working prototype was ready; now, Porticos engineers have supported units through in-depth product manufacturing and market testing. Continue reading “Introducing Livi™—your new home healthcare aid!”

A Next-Generation Blood Clotting Test for the Point of Care

If you’re bleeding, how does the doctor know whether you need a transfusion? How does she know how much to give, or when to stop? Today there are diagnostics tests that provide this information, but not enough hospitals use them beccause they’re expensive, complicated, and unreliable. What if there was a simpler test that was small and easy-to-use? Transfusion outcomes would improve and hospitals would save money.

Rheomics LogoThe Chapel Hill-based startup Rheomics is developing a device to solve this problem. Using Rheomics’s patent-pending Actuated Surface-Attached Post (ASAP) technology, doctors will be able to direct transfusion therapy using only a pinprick of blood in a simple, effective test.

A device, using Rheomics’s patent-pending Actuated Surface-Attached Post (ASAP) technology, that doctors will be able to use for a simple, effective test using only a pinprick of blood.Rheomics contacted Porticos because they needed to demonstrate that their technology could be packaged in a compact, low-cost device. Continue reading “A Next-Generation Blood Clotting Test for the Point of Care”

Novel Medical Device Automatically Monitors Patient Temperatures

Protective hypothermia, a medical treatment that lowers a patient’s body temperature, helps to reduce the risk of tissue injury due to insufficient blood-flow after cardiac arrests, strokes, or traumatic brain injuries. Water blankets and wraps have been used to lower patients’ body temperatures since the 1950s, but they can overshoot the temperature goal. The Navy and Air Force Medical Services Agency recently contracted a team to develop a smarter sensor device to help manage patients’ temperatures automatically. Porticos developed the mechanical system for this innovative project Continue reading “Novel Medical Device Automatically Monitors Patient Temperatures”