DNA Analyzer

The BD Viper was created to simplify the logistics of multiple STD testing and to eliminate the trade-offs between cost and turnaround time that is commonly faced by healthcare providers. This testing is accomplished through DNA amplification technology. This methodology is considered to be more sensitive and specific than conventional non-amplified tests and can identify a number of infections that would previously have gone undetected and hence untreated.

When we were first introduced to this project the Viper was nothing more than a very preliminary breadboard concept with a few basic components placed on a work surface.

Integrated Design Systems was contracted to transform this breadboard into a production medical device by concurrently working with the engineering development team at Becton Dickenson. Our specific responsibilities included the conceptual and production design of the entire structure, including covers, as BD’s engineers developed the internal functional modules.

This complex system required a critical review of all design parameters affecting the structure and covers. Therefore the first design phase included a comprehensive investigation into product requirements which were compiled in a specification report.

A CAD assembly of components was concurrently developed to begin evaluating the overall architectural layout of the system.

The original very basic assembly layout was developed to include a lower base frame as shown in this picture.

Ergonomics and human factors were critical to the design of this large complex system which was to be sold worldwide. One of our key challenges was accessibility to the work surface which was dependent upon the robot arm and arrangement of sample modules. After brainstorming numerous alternatives we decided that a curved rotary door panel design would provide maximize accessibility using minimal floor space. We constructed a few iterations of foamcore models to verify optimum placement of components.

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.

Some of these concepts were also modeled using SDRC which was used throughout the project. Concepts were intentionally kept simple to quickly study numerous forms, one of which would later establish the foundation of the product’s image.

Selected concepts were refined to a higher level of detail as shown in these concept renderings which initially included some suggestions for materials and later finer features such as the work surface.

After evaluating these concepts based on tooling costs and other technical parameters, the latest design iteration was refined based on a combination of sheet metal and pressure formed covers.

Immediately after the concept design was approved by marketing, we began translating it into a real product. This phase required extensive file transfers between both companies since the design was being developed concurrently. The following pictures will provide you with an extremely abbreviated history of how the accepted concept developed into a production design.

Frame

Extensive time was dedicated to developing a viable design methodology which would facilitate easy assembly and removal of covers with difficult alignment procedures. Our premise for attaining this objective was to design a centralized framework which would act as a common reference for all covers.

Door Track

The cantilevered clear acrylic doors were designed to pivot from a central point off the rear of the frame as shown in the previous pictures.

Final CAD Details

The entire CAD cover and structural assembly was detailed with BD’s engineering team by maintaining very close communications through frequent file transfers and phone calls. Eventually all parts were completely detailed for production as summarized in the following photographs.

Final Covers

The following photos will highlight some of the pressure formed parts that comprised the worksurface. In addition to human factors considerations, the work surface was designed to trap liquid spills with special overlapping joints. Covers were also designed for ease of assembly, disassembly, and cleaning.