Dhara Amin, Michael Brennan, Eric DiBlasi, Andrew Smith Team LiteCure Dhara Amin, Michael Brennan, Eric DiBlasi, Andrew Smith

Background LiteCure: Manufacturing company for medical devices involving advanced laser technology for the health care and veterinary industries. Products: Deep tissue therapy units that use laser technology to accelerate the body’s natural healing process. Products are typically housed on a cart to allow the device to be transported from one patient to another in clinical settings

Motivation LiteCure is in need of a custom cart design that solves several problems surrounding their current cart design. Issues: Poor fiber optic and power cord management Lack of accessory storage and securing of those accessories Aesthetic image of the cart Ease of use and functionality improvements Current LiteCure Cart

Project Scope Deliverables For Sponsor To design an aesthetically pleasing utility cart for LiteCure’s deep tissue therapy unit that coincides with their desired image and allows users to easily access and store all components of the unit in a clinical setting. Deliverables For Sponsor Full Drawing Package of Final Concept Manufacturing Details Assembly Details Prototype

Product Line 15 Watts 9 watts 12 watts 10 watts

Hand Piece and Fiber Optic Cord Fiber Optic Cable: 3 meter length Minimum bend radius of 3 inches

Product Accessories Patient Glasses Operator Glasses Laser Head Attachments “Doggles” (Veterinary Use) UPS System Foot Pedal (10 Watt Unit)

Benchmarking Cutting Edge K-Laser Anthro Cart UD PT Clinic Anthro Cart Should replace Anthro design with the vet clinic cart Cutting Edge K-Laser Anthro Cart UD PT Clinic Anthro Cart Vet Hospital

Design Requirements Compatible with product line Aesthetically pleasing Low cost Easy to use Safe

Product Compatibility Need/Want Metric Test Target Value Support Weight of Laser Unit and all Accessories Weight Capacity (lbs) Failure Testing: Statics Calculation >= 50 lbs Accommodate each unit of product line Platform dimensions (in) Platform can accommodate largest unit (16.25 x 10.5 in) >=16.25 x 10.5 in Storage space for all accessories: (Safety Glasses, Head Attachments, Foot Pedal, UPS) - Is there storage for all required accessories? Y Stores Fiber Optic Cable Is there storage for Fiber Optic Cable? No blockage of Vents Are all vents open to air flow? Height Inches Measurement 30 inches Potential questions: Why isn’t there an upper limit to the weight capacity? We need to weight all accessories, also implement a safety factor.

Aesthetically Pleasing Need/Want Metric Test Target Value Company Image - Survey Customer Review Geometry Futuristic Material Selection Surface Finish Casters

Low Cost Need/Want Metric Test Target Value Manufacturing Price Per Cart Machining/Forming/Material Cost ($) Quotes/cost calculations $500-$700 Packaging Shipping Weight (lbs) Shipping Volume (in^3) Packaging weight and volume calculations 35 to 50 lbs < 3 ft^3 Number of Tools Required For Assembly Number of Tools (#) How many tools are required? 1 Where did we get a $100 for raw material cost?

Easy to Use Need/Want Metric Test Target Value Quick and Easy Removal and Replacement of Fiber Optic cable # of wraps, wrapping radius (in), time to wrap (s) Time Test, Survey 5 wraps, >=3” wrapping radius, <30 seconds, Customer Review Easily roll and transition over different floor mediums Pulling Force (static and dynamic) (N) Rolling Test Passes Test (exceeds or meets current cart results) Accessory Placement Time to remove and store accessories (s) ~ 30 seconds, Customer Review Cable Management: Fiber Optic, Power, UPS, Foot Pedal # of hanging cords, time to wrap (s) 0, <30 seconds, Customer Review Target values were obtained from testing the current LiteCure cart Need to get actual metric for rolling test

Easy to Use Need/Want Metric Test Target Value Easy to Clean - Can cart be cleaned with bleach, cleaning spray, or wipe? Y Easy to Assemble Time to assemble (mins) 5-15minutes Ergonomics: Shelving Survey: Are the shelves easily accessible and/or adjustable? Customer Review Target values were obtained from testing the current LiteCure cart

Safety Need/Want Metric Test Target Value Stability Tipping Angle (Degree) Tipping Test: At what angle does fully loaded cart tip? 10 degrees Avoid Sharp Edges/Corners Number of Sharp Edges (#) - Locking Wheels Number of Locking Wheels (#) Count number of locking wheels Minimum of 2 These metrics will be used to rank the team’s concepts except some tests cannot be performed until a prototype is made so we plan to make a few prototypes and rank them based on all the metrics.

Our Process Mockup Testing Preliminary Designs Final Design Sponsor Feedback Design Details Final Prototype

Basic Component Design Platform: Where the units sit Structure: Body of the cart Base: Bottom of the cart: Where UPS sits Caster Selection: Caster size, type, and vendor Accessory Design: Compartments for: Fiber Optic Cable, Safety Glasses, Foot pedal, Head attachments

Structure Design

Structure Design

Platform Design

Base Design

Thermoplastic Elastomer Caster Selection Structure and Wheel Material Single Wheel Caster Thermoplastic Polyurethane Polyolefin Thermoplastic Elastomer Twin Wheel Caster

Caster Selection Fastening Type: Other Considerations: Top Plate Threaded Stem Grip Ring Stem Other Considerations: Wheel Diameter: 3 or 4 inches Locking Wheels: yes or no Swivel: yes or no Load Capacity: at least 50 lbs Warranty: at least 2 years

Manufacturing Research Anthro: Materials used for shelving Capabilities of a wood laminate design Cart structure material Minimal welds in design Extreme Machining: Press breaking capabilities Tube bending practices Water and laser cutting capabilities

2nd Iteration Design

3rd Iteration Design

4th Iteration Design Chose C-shaped structure Added a locker Incorporated the feel and lines of the LiteCure devices Material: Carbon steel sheet metal

Mockup Material: Wood Casters: 4-inch and 3-inch Standard hardware Mockup used for the following purposes: Perform tipping and rolling test Evaluate casters Perform field test (in PT clinics) Results: Increase length and decrease width of platform Front door design

Customer Review Design: UD PT Clinic and LiteCure office used mock-up for three days and took survey. Customer review measures: Ease of Use Aesthetics Easy accessory placement Easy shelf accessibility Adequate storage Easy to transport Adequate cord management Quick/Easy Wrapping and Removal of Fiber Optic Cable Cord Management Adequately display company logo Futuristic feel Appropriate Geometry Appropriate material selection (sheet metal) 4-inch casters preferred

Customer Review Results: Aesthetically appealing Functional Satisfactory cord and fiber optic cable management Customer Review results for the questions asked about cord and fiber optic cable management. The mean values for the question are represented with correlating standard deviations. Survey Scale: 1 –Strongly Disagree , 2 –Disagree, 3 –Neither Disagree nor Agree, 4 –Agree, 5 –Strongly Agree

Mechanical Testing: Tipping Mention Standard (10 degrees) and measured tipping angle front, back, and side with load taken into consideration. Worst Case 4 – inch Casters 3 – inch Casters Current LiteCure Cart Sideways Tipping Angle 11 degrees 15 degrees

Stress Analysis Worst Case Scenario Bending of the platform and shelves point load in the middle Pull out force for PEM Fasteners

Final Design Material: 14 Gauge & 16 Gauge Carbon Steel Casters: 4 inch diameter Fasteners: PEM fasteners Features: Back locker, front door Storage space: 1.9 ft^3 Height: 30 inches Weight: 65 pounds

Final Design: Aesthetics C – Shaped cart with curves and lines similar to LiteCure devices Color scheme can be used for both product lines Space for logo Finish: Powder coated paints Larger 4 inch casters

Final Design: Platform One size platform for multiple devices Refined dimensions Perimeter around device Hole for cord management

Final Design: Structure Wide base for stability PEM fasteners attach all parts Flanges on shelves add strength Converged to aesthetic design based on sponsor feedback

Final Design: Additional Features Front Door: Easy access to goggles and head attachments Goggles stored in mesh bag on front door Speed controlled hinge Back locker Easy access to all shelves UPS and miscellaneous storage space Rotating latch

Final Design: Additional Features Fiber Optic Management Hook design Quickly drape cord over hook Secure hand piece on device Power Cord Management Hole in top platform Hole in back locker door Internal guide for cords

Cost Analysis Quote of 1 Cart (machine shop) $1460 Does not include: PEM Fasteners, McMaster Hardware, Casters, Front Handle, and Fiber Optic Cable Management Hook. Quote for 1000 number of units (machine shop) $200 - $225 a unit Hardware Cost: About $31 a unit PEM Fastener Cost: About $30 a unit Casters Cost: About $34 a unit A thorough cost analysis could not be obtained because company is going to manufacture who has different pricing. But with this price everything but plastic parts are considered

User Instructions Assembly PEM fasteners press fit in to side panels Detailed instructions for assembly Only 1 tool needed: Wrench Packaging Cart can be broken down in to smaller, flat parts Box dimensions: 27.5 in x 27.75 in x 6 in

Design Validation

Path Forward Give LiteCure drawing package and assembly instructions. LiteCure can take design to manufacturing company for start of mass production. Small changes may need to be made to the design in order to be manufactured by a specific company. More testing to sheet metal prototype: accelerated wear and overload testing