Recent Projects

Units are required to be water proof to IP68, water & air tight to +/- 1atm from sea level (cargo hold of air travel – to -33ft deep in water) with no change in the unit when held in your hand at ground level.
Top cover is an insert molded part with a 60 durometer Santoprenematerial to allow activation of 2 switches.
Design was verified by running FEA before beginning tooling

Develop a surgical trainer with Encoris for training on the lower-mid spine (Sacrum-T8)
Unit required an LED light down center, 4 cameras that can be exported to a presentation tool (software) on a computer & to be run by battery, which allows the unit to be stand alone.
Camera’s were also required to follow the lordotic curvature for a true view of the vertebrae, which the side rails provide for the camming action with a glide down the center.
Combination of CNC acrylic base, Vac-Formed torso, cast urethane bone structures and mounting blocks for camera mounts. Other hardware were stock components.

Develop injection molded parts that would allow an LED to be visible, and function with off-the-shelf motion sensor & lens.
The unit was required to pass water testing and UL 5VA flame ratings. This was achieved by creating hazardous path features on the housings (no rubber seal) to keep cost down, and a sonic welded lens for the LED. The off-the-shelf lens was supplied with a seal and sonic weld ring to capture it in a sub-assembly with the sonic welded LED light pipe.

Develop a single injection molded part that would allow an LED to be visible, and a light pipe to activate a light sensor. Required use of off-the-shelf motion sensor & lens as well.
PCB had to be mounted vertically, wired and connected to an existing cast aluminum housing. The unit had to pass water testing and UL 5VA flame ratings as well.
By using a clear Polycarbonate material we found listed on UL’s site and some o-rings, we were able to meet the above criteria without more involved UL testing.

Working with local company and designer (BeckFoleyLLC), we developed a headrest that can be attached to the Herman Miller Aeron chairs.
The goal was to achieve fore/aft adjustment as well as height and tilt adjustment, and clamp to all 3 sizes of chairs.
Working with the industrial designer, we developed a method of attachment and smooth motion that was acceptable to everyone, including manufacturing.

This ski was developed with a Michigan based company for cross use as a cross country ski and a down hill ski. The ski required a mix of features for both types of skiing and wide enough to work a bit like a snow shoe.
The bottom has scales similar to cross country skis to help climb small hills.
The design direction for manufacturing was blow molding with threaded inserts for mounting various bindings. We worked closely with the molder to select material, fillers and design criteria for tooling to achieve the desired strength and function.

This device was designed to have a touch screen and survive a 3’ drop test on each corner multiple times. There is a small side button for power on/off, and a USB connection on the bottom. Lastly, there is an IR transmitter/receiver located on the top right corner with special designed light pipes to achieve proper function at a specified distance.
This was achieved by making 3 main parts, front, mid-frame, and battery cover; plus the light pipe and a small LCD frame. The LCD is made with Gorilla glass to assist in the drop tests.
The mid-frame and front are screwed together capturing the PCB and LCD (which is located by the small LCD frame) to create a solid product that can withstand such abuse. The battery cover was then designed with snaps that may allow it to be dislodged from the product with minimal damage, and be snapped back on.

This device does not need to be sealed for outdoor use, but does need to exhaust heat from the electronics inside.
A tight mesh screen (similar to typical window screen) is located in bottom and around top perforation to allow an internal fan to pull air through the electronics and exhaust out the top.
A thermal box with a Peltier is used on the box to maintain constant temperature for air sampling.
WiFiAntenna’s are used for network connection and reporting.
The stand and straps are interchangeable for mounting needs, 2.5”-5” diapole, or table mount.

Designed to monitor high risk patients and limit liability for patients who are under orders not to get out of bed or require assistance.
Designed for wall mount only.
Interface panel on back for ethernet and operation.
Full view camera on bottom and vented at top. Use of special colored material for camera dome was required to semi hide camera and allow max use.
Speakers in front so nurses/doctors can speak to patient in room remotely.
Semi-tamper resistant by use of security screws on top and bottom caps.

Designed for travel use, in its own case, one can filter their own water in their hotel room.
Adapters designed for use with pitchers, and development of their own pitcher for use with this filter.
Carbon combo filter device denoted with month to track use and time to change out.
Top just simply twists on/off with a light friction snap to allow replacement of filter.
Lower section is hard plastic overmolded with Santoprene for grip.

Designed with a suction cup mount for easy removal for cleaning.
Holds 2 packs of produce preserver material.
Cover designed to latch at top with molded in hinge on bottom, just snaps together.
Top latch designed with secondary part to allow for a user instruction card that can be changed out.