Integrated Design

The DCA 2000+ was originally offered by Bayer as a feature enhanced blood diagnostic desk top analyzer based on the previously highly successful DCA 2000 which was designed by IDS a few years earlier. Although It is currently manufactured by Siemens, its function as a point-of-care diabetes management platform has not changed since it was introduced more than 15 years ago. The DCA 2000+ performs both hemoglobin A1c and microalbumin / creatinine tests in minutes. Health care professionals can perform quantitative measurement of HBA1c in blood to reduce the risk of retinopathy, nephropathy and neuropathy in patients with diabetes. The system also measures low concentrations of albumin, creatinine and albumin/creatinine ratio in urine. The method permits decentralized testing using random urine samples, enabling early detection of complications associated with renal disease.

Objectives

The objectives for this project were quite straightforward. Our design firm was contracted by Bayer to develop alternative design variations for the DCA 2000 that would impart a new appearance based on three investment options.

The first option was based on a minimal investment using the existing covers and introducing a few minor detail changes.

The second option included a completely new set of plastic covers based on the same component arrangement.

The third and last option was based on the freedom to rearrange components as well as explore new design possibilities.

Concepts were to be evaluated based on feasibility, estimated development costs, benefits, and risks in addition to overall tooling costs.

Before concepts were developed, our design team documented the operation sequence for the new product. In addition we outlined the design limitations associated with each option based cabling, connectors, PCB orientation, and air flow requirements. Concepts were initially developed as rough thumbnail sketches to explore as many interpretations of each alternative.

A minimum of three concepts were presented based on the use of existing covers with minor changes to colors, a limited number of plastic parts and a new display cover with a new membrane keypad.

The second option of exploring design alternatives on the current component layout and a totally new set of plastic covers was also presented.  These concepts illustrated significantly different appearances without disrupting the existing layout of internal components. However, tooling investment would be significantly greater when compared to the first set of alternatives.

This third and last option explored design alternatives based on different component arrangements and a completely new plastic enclosure. These concepts provided a radically different appearance when compared to the DCA 2000. The overall footprint, style and orientation of the device was redesigned in many different configurations as illustrated in the following renderings.

Full scale foam block models were constructed based on a selected group of concepts to provide marketing and management with a physical representation of size and shape for each concept.

After carefully evaluating investments, risks and financial benefits, Bayer’s management and marketing people decided to limit design modifications to the minor changes as described in Option 1. The selected concept was ultimately finalized as shown in the following photographs. Design modifications were limited to color changes, and three sections of the product which included the top LCD cover and control panel, the door grip and the side vent cover. These restricted design revisions updated the overall appearance as originally planned with minimal capital investment.

The addition of blue/green color highlights on the access door handles and air intake cover enhanced overall appearance by applying the same color to the control panel overlay. A rounded form was used on these details to compliment the more prevalent geometric forms defining the product. A slightly domed surface was added to the air intake cover which made the form of the cylindrical sample handling compartment more finished. Louver slots were intentionally oriented to align with the general direction of the main product sloped face. This detail greatly added to the overall integration and appearance of the design.

Mechanical details of the air intake manifold were equally well designed to comply with ease of use and molding requirements. The light grey exterior cover was designed to be easily removed by a technician to replace a paper air filter sandwiched in between it and the inner blue/green cover. Details of the snap lock joint are shown in the following photographs. A slight dimple was included in the design to provide a positive snap lock to the partially turned and locked cover.

This photograph of the door shows the assembly of the main door to the ultrasonically bonded handle which formed a comfortable and very clean looking assembly.

The membrane keypad was added to the upper portion of the analyzer with a wraparound tab to impart the three dimensional look of a colored insert. In addition, the buttons were designed with a subtle shaded tone to impart an embossed impression. Application of this larger graphic overlay reduced the disproportionately small area occupied by the LCD and visually aligned the display area with the cylindrical form located on the lower portion of the device.