When it comes to human-machine interfaces (HMIs) intended for the medical and pharmaceutical sectors, state-of-the-art technologies are vital to the manufacturing process. After all, achieving superior reliability and precision is the ultimate goal! Strict standards govern the design, testing, prototyping, manufacturing, and packaging of such a product. The environment in which the device will be used and the operating conditions must also be taken into account.
Join us as we unlock the secrets behind the design and manufacturing process of a custom HMI for the medical industry by taking a look at one of our most recent projects.
The project: a device that guides surgeons during knee operations
Engineers at Zimmer Biomet created an electronic device with small LED lights to help guide surgeons during surgical interventions, but they needed a graphic overlay that could be attached to the top of the device to finalize the project.
Extreme precision: a major challenge!
In order to provide reliable data to surgeons during operations, the graphic overlay required precise measurements and carefully printed graphics. Repeatability had to be achieved prior to manufacturing, and each element’s measurements had to be calculated to one-hundredth of a millimetre.
Stringent quality control checks were carried out to ensure that the printed elements (achieved through screen-printing-style serigraphy and digital printing) were the right size and in the correct position so that they were, among other requirements, perfectly aligned with the contours of the small LED lens.
A carefully monitored manufacturing process
Our team had to complete three different stages to obtain the final result.
- TESTING AND PROTOTYPING
Thorough testing was carried out on our prototypes, which allowed us to identify minute measurements using our digital microscope and a computer measurement machine, or CMM. The digital microscope allows us to reach measurement precision of up to 0.1 µm for certain elements. We were able to eliminate the margin of error associated with human verification by measuring embossed elements, defining the thickness of the inks, and measuring certain printing lines using our state-of-the-art equipment.
Compliance approval is obtained by providing rigorous documentation detailing the design, prototyping, and testing processes. All data, changes, and test results must be documented, shared with the client, and archived. Once the objective is met, a certificate of compliance is issued with each shipped order, and the traceability of each batch is closely monitored.
Each unit had to be packaged in a way that prevented any dust or residue from coming into contact with the product. Factors such as heating, ventilation, air conditioning, and air purification were strictly monitored throughout the manufacturing and packaging process to prevent the circulation of dust particles. This also allowed us to produce graphic overlays with optimal print quality.
Accurate and reliable results that exceed expectations
For this project, the product and process development took nearly 1000 hours of work. To complete the project, we created 25 prototypes, scaled hundreds of products, and validated thousands of units! Throughout the process, every stage of planning, design, and manufacturing processes was validated by the client, who also helped enhance the final product thanks to their valuable ideas and feedback.
The client is satisfied not only with the product’s high degree of precision — custom-made for their specific needs — but also with its reliability and user-friendly features.
State-of-the-art equipment and evolving expertise
Our new high-tech factory is equipped with cutting-edge automated printing and cutting machines, sophisticated measuring equipment and an air quality control system. Whether it’s for just a few prototypes or high-volume manufacturing, our experts can optimize the electronic, aesthetic, and ergonomic specifications of each device and overlay.
When it comes to HMIs intended for the medical and pharmaceutical industries, Memtronik is committed to the pursuit of excellence and innovation. We’re currently working on improving biosensor technology, which is used for various applications. In the next few years, we hope to continue our research by setting ourselves apart in terms of precision, repeatability and traceability.
The manufacturing of HMIs for the medical and pharmaceutical industries requires the kind of precision that only experts can provide using rigorous processes and state-of-the-art equipment. That’s exactly what Memtronik has to offer. We pay attention to your needs and concerns while generating innovative ideas to help you develop the perfect prototype.
We can’t wait to hear all about your needs, challenges, and thoughts on your project. Let’s schedule a meeting!