Case study
Rapid prototyping a novel mechatronic diagnostic system
Detailing the hands-on development of a complex diagnostic proof-of-concept, combining novel mechatronics, fluidics, and electronics.
The challenge: Proving the viability of an advanced diagnostic concept
Before committing to a multi-year, multi-million dollar product development cycle, we needed to answer a critical question: was our advanced concept for a next-generation diagnostic system technically feasible? The design called for the complex integration of several novel technologies, including precision microfluidics, advanced optics, and innovative mechatronics, all on a single, low-cost consumable. The challenge was to build a functional proof-of-concept that could validate these core technologies and de-risk the enormous investment required for full-scale development.
Our solution: Hands-on, first-principles prototyping
We took a deeply hands-on approach to rapidly prototype and verify the core systems. This involved going back to first principles, moving from component datasheets and breadboards up to a fully integrated system.
1. Building the electronic brain: The initial hardware development started on breadboards. We implemented the core electronics and board-level logic (I2C) directly from component datasheets. This ensured that our foundational electronic concepts were sound and functional before we committed to the time and expense of custom PCB fabrication.
2. Engineering novel mechatronics and fluidics: A key innovation was a unique system for fluid control on the consumable itself. We designed and prototyped novel mechatronic actuators and a unique fluidic architecture capable of filling multiple reaction chambers in parallel from a single source. The design incorporated passive flow-control features, a critical element for enabling complex tests while preventing cross-contamination.
3. Optimizing for manufacturability: The disposable consumable was designed for high-volume injection molding. To ensure its viability, we used Moldflow FEM software to simulate and optimize the design. This was critical for validating the feasibility of molding the part's complex microfluidic features and the ultra-thin "windows" in the reaction chambers, which were essential for tight temperature control of the assay.
4. Integrating high-performance optics: The system required a high-sensitivity dual-bandgap fluorescence optical system for analysis. We integrated high-power LEDs and precision optics into the prototype to ensure it could meet the demanding performance requirements for accurate diagnostic analysis.
The impact: A validated concept that accelerated development
This hands-on prototyping effort successfully created a functional proof-of-concept that validated the core, high-risk elements of our design. By proving the viability of the electronics, mechatronics, and fluidics—as well as the manufacturability of the consumable—we de-risked the project and helped establish technical confidence and core architectural concepts.