Integrated Design

The Viper was created to simplify multiple STD testing and to eliminate a problem commonly faced by healthcare providers, namely the trade-off between cost and turnaround time. The testing, accomplished through DNA amplification technology, is considered to be more sensitive and specific than conventional non-amplified testing, and can identify infections which would previously have gone undetected and untreated.

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When IDS first approached this project, the Viper was nothing more than a preliminary breadboard concept with a few basic components, placed on a standard work bench. The foundation of this complex system was based on a high speed, commercially available robot, able to transfer reagents and samples quickly from one reaction station to another. One of many design challenges was to maximize the sample population density within the surface area of the robot’s reach, while optimizing human factors considerations for the operator. A complication was the need to minimize floor space and transport an oversized product through conventional door openings. IDS’ objective was to transform this breadboard into a production medical device by working with the Becton Dickenson engineering development team. IDS was responsible for the conceptual and production design of the entire structure, including covers, while Becton Dickenson engineers developed the internal functional modules based on the concept previously described. Such a complex system necessitated a thorough examination of all design parameters affecting the structure and covers. IDS documented this extensive body of information in a comprehensive specification report, which was formally presented to Becton Dickenson during the project’s first phase.

IDS prepared quick sketches of the components and basic structure to assist in the visual layout of the system. These loose sketches provided an efficient means of communicating rapidly with other project members. Notes were added to drawings to document critical facts, which would ultimately influence the general design direction.

Shortly after the sketches were reviewed, a preliminary CAD assembly of major components was created. This enabled the development team to assess accurately the overall architectural layout of the system. The original 3D assembly included the robot arm, a general representation of sample trays, a disposal container and some other essential components.

After studying the layout, it became obvious that the robot’s large radial motion was a major influence on the overall design and product appearance. A dominant cylindrical form for the front of the analyzer was immediately apparent, based on ergonomics and functional considerations. Easy access to the whole work surface area for 95% of the population was essential. Ergonomics and human factors were therefore critical design considerations, which had to be evaluated without any assumptions or oversights. Construction of numerous foamcore models enabled IDS to evaluate reach, operator interaction, configuration, and lighting, based on different layouts.

At the same time the ergonomic studies were being conducted our design team began developing concepts for the overall form. These sketches are only a few of the hundred or so concepts that were explored base on product images. All concepts were based on a cylindrical front access area that would be opened with circular sliding doors. Form studies ranged from very geometric shapes to more abstract freeform configurations. The purpose of this exercise was to freely explore new ideas that could lead to an interesting embodiment for this very large analyzer.

Some of these concepts were also modeled in 3D CAD based on numerous simple form studies, which provided abstract thumbnail shapes of the product. Limiting features to simplified abstract shapes enabled the team to explore many ideas efficiently and thus identify dominant forms, which would later establish the foundation of a unique product image.

One concept was selected and further refined with details, including materials, displays, work surface components and other elements visible to the operator. The concept was initially rendered with complex surfaces based on extensive use of plastic. Although the shape was interesting, unique and visually appealing, the client’s reassessment of capital investment in molds required a design modification, limiting the use of plastic covers to essential areas. The outcome was a unique and arresting design, which satisfied all the design objectives. A combination of sheet metal and pressure formed plastic resulted in a restrained classic design that surpassed all previous concepts.

Immediately after approval of the concept design, IDS began the demanding task of translating an attractive concept into a real product. There were complications: numerous technical issues, budgetary restrictions and an aggressive timeframe. The ambitious project required extensive file transfers between both companies and a cohesive development plan to assure successful completion on a restricted schedule. Transitioning the concept into a production unit required segregation of  the product’s functions into discrete areas. These areas were grouped into the base frame, work surface, upper frame, sliding doors, operator interface and exterior covers. Within each section, individual parts were detailed according to functional and manufacturing requirements. The following pictures illustrate an extremely abbreviated history of how the accepted concept developed into a production design.

The rotating clear acrylic door panels, designed to be cantilevered from the rear wall of the upper frame and pivot from a central point off the rear wall, were a significant challenge. Considerations of structural integrity, smooth motion, simplicity and ease of use were given top priority from the beginning. The design also accounted for generous tolerances and ease of assembly. Specification of rigid tubular aluminum as an underlying framework to support the covers was critical to the structural integrity necessary for supporting the cantilevered doors. A separate molded guide trace within the work surface ensured easy rotation of the doors in their respective tracks, without colliding or binding.

All plastic parts were designed for the pressure forming process to satisfy restricted tooling budgets and aesthetic considerations. Every facet within each plastic part was skillfully detailed to meet the selected molder’s tooling and molding requirements. Also, parts were designed to comply with post molding operations, including trimming, additional mounting bosses and machining. The following photos highlight some of the pressure formed parts comprising the work surface. In addition to human factors considerations, the work surface was designed with special overlapping joints to trap liquid spills. The complex covers were also devised for ease of assembly, disassembly, and cleaning.

The resulting product was a major triumph for Becton Dickenson; its Vice President hailed the Viper as one of the company’s most successful products. The Viper was also recognized by the SPE’s Pressure Forming Division’s Best Product Design. Pictures give more information than words: the following images demonstrate the exceptional design and detail of this product. It stands as a milestone in technology for one of the world’s leading medical companies, and as a testament to the talents and capabilities of IDS.

The work surface was completed as originally intended. It provided optimal operator access to any area without compromising robot access or speed. It also permitted service personnel to remove any section easily, using conventional tools. Overlapping troughs in the plastic covers prevented liquids from spilling on to the lower deck.

A slide out keyboard tray delivered easy access to a computer keyboard when required. The slide out feature provided protection to the keyboard when not in use, while also eliminating any obstruction to the operator when accessing sample trays. The keypad was strategically positioned in proximity to the LCD screen.

Structural details for sliding doors, waste bins and other areas were designed to comply with the functional requirements and manufacturing methods specified for each part. The resulting product maintained a consistency of visual and functional integrity throughout.

The Viper remains a flagship product for Becton Dickenson and has helped secure the company’s position as a world leader in medical technology.