Bennett X-Ray
Millennium 2000 X-ray system

The Millennium 2000 project involved a complete redesign of an entire x-ray system which remained unchanged for more than 20 years. Improvements in overall appearance, human factors, ease of service, structural integrity, and lower manufactured cost were realized in the new system design. Extensive use of plastics, castings and extrusions resulted in a system which conveyed world class quality at a competitive price.

The scope of this ambitious project was extremely comprehensive, including every phase of product development ranging from market analysis to production liaison. An abbreviated description of the design evolution will be discussed in this case study, starting with product research.

Before any design work was initiated, we conducted a comprehensive study of the existing product line. Our research included markets segments, competition, user interface, ergonomics, manufacturing and service parameters related to the product line. A comprehensive HTML document was prepared at the beginning of this project to document all product requirements and specifications.

As we approached the completion of our product research phase, it became apparent that the critical user focal point was the x-ray tube head design. We therefore began developing concept sketches for the head which would eventually establish an overall style for the product line.

A selected group of these sketches were translated into physical 3D foam models which were evaluated based on human factors considerations. This ergonomic study was critical to the overall design and operation of the system by a trained x-ray technician.

Each of the foam models were developed to optimize operator interface after critically analyzing evolutionary design iterations.

The human factors study was followed by development of 3D CAD generated concept layouts for the x-ray head as well as the entire system. These refined concepts were based on inspirations from previously developed sketches. Our objective during this stage of design was to create a unifying image for the entire product line with form, colors and specific design details.

One of these developed concepts was further detailed to include more features pertaining to control buttons, colors and proportions as shown in these pictures.

Throughout the next two months our team of designers translated this vague concept into one complete set of fully detailed production ready parts for the entire system. Designs for thousands of parts required an intensive effort and attention to details at every level of development. Mechanical design, structural analysis, costs studies and designs for every part ranging from gas assist molded plastic parts to sand cast aluminum components were all fully detailed for production tooling. Machined parts, component selection and constant verification during every step of development resulted in the successful completion of a fully operating system well before the scheduled date.

Graphic design of control panels and keypads was another detail that was completely developed by our design team. These critical areas of the system required a subtle balance between human factors and aesthetics for safe operation of the equipment. Concepts and camera ready artworks were completely designed by our team. Examples of artworks for the collimator and keypad are shown in the illustrations below:

 

 

Throughout the design development phase, CAD files were distributed to selected vendors for part and tooling price quotes based on various manufacturing processes. The spreadsheets below provide examples of how costs were estimated. These analyses provided our client with comprehensive and accurate information to determine the optimum manufacturing processes for manufacturing the system.

 

Concurrently with the design completion of every sub-assembly, part files were released to specified vendors for construction of prototype parts.

 

Five complete systems were fabricated utilizing stereolithography for plastic parts which were eventually cast in polyurethane. These parts can be reviewed at various stages of completion in the photos. Sand cast aluminum were also derived directly from 3D CAD files based on rapid prototyping methods. Extra material was included in CAD files for post machining of critical surfaces.

 

The complete system was introduced on time at the annual RSNA show with resounding success. These pictures illustrate how the product was displayed and demonstrated to the attending audience.

 

A comparison of the new design and the original system are depicted in the following photographs. Even a casual viewer can readily appreciate the dramatic difference between both systems.

 

An overview of the complete system is shown in the illustrations below: