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Rigiflex Joins Hands with a Leading Medical Device Manufacturing Organization

Developing a Unique Design for MRI Machines

Rigiflex has been working with a renowned medical device manufacturing organization for some years now. This organization has been developing breakthrough products in the medical industry used specifically for X-rays, radiology, security, and more. Recently, this organization was commissioned to design a prototype for a handheld medical device. The product had to be compliant with IPC and UL standards. This device was to be used in Magnetic Resonance Imaging (MRI) machines.

PROBLEM

The in-house PCB design team at the medical device manufacturing organization faced the following issues:

  • The many designs that were developed previously were not compliant with UL and IPC standards. This posed a problem, so the design had to be modified.
  • Due to the client’s corporate policy, all components had to be sourced from limited number of vendors. Hence, availability of some components was limited.
  • The PCB had to be survive several drop tests. (This was a challenge since the PCB consisted of 18 layers.)

SOLUTION

The medical device manufacturing organization worked closely with Rigiflex to develop a feasible solution. Rigiflex used a highly systematic method to design the layout of the PCB. All the components needed to develop such a PCB were listed out. This was checked against the client’s vendor inventory. We made the right modifications to the components used to align our requirements with those available with the vendors.

Constant checks were made to ensure there were no weak links in the circuitry. Since the PCB was 18-layered, Rigiflex also ensured that the interconnections were strong. The joints of a PCB are its weakest points. Hence, we had to make sure that they were reinforced and would be able to endure the drop tests. The final product did not break when we performed drop tests. Over 100 drop tests were performed.

The circuitry was also designed in a way that there was no overlap on adjacent layers. We integrated rigid flex circuitry into the PCB to ensure that the construction was tough and could endure rigorous functioning for long hours. We had to make sure that the functioning of the components was not affected by high frequency radiations, electromagnetic interference, or other interferences. This is important since a hospital uses these radiations for MRIs, radiology, CT scans, etc.

We made use of the client’s expertise on the operational front of the device to improve on the functionalities of the PCB to make the end product more user-friendly.

We at Rigiflex used our expertise to develop this solution in a matter of eight days. With a lead time of 20 days, we were able to manufacture the final product. Our engineers also incorporated some methods to ensure maximum cost savings. The processes used for manufacturing, component sourcing, and product testing were performed in compliance with IPC and UL standards.

BENEFITS

The client received a product that:

  1. Is IPC and UL compliant
  2. Could endure 100+ drop tests
  3. Could be used continuously for long periods of hours without overheating
  4. Consisted of components from a select list of vendors
  5. Is unaffected by high frequency radiations and electromagnetic interference
  6. Is user-friendly
  7. Manufactured in a short lead time
  8. Is cost effective

 

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