Dhara Amin, Michael Brennan, Eric DiBlasi, Andrew Smith

Team LiteCure

• 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

Background

Motivation

Current LiteCure Cart

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

Project ScopeTo 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

Hand Piece 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 CartUD PT Clinic

Anthro CartVet Hospital

1. Compatible with product line2. Aesthetically pleasing3. Low cost4. Easy to use5. Safe

Design Requirements

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?

Y

No blockage of Vents - Are all vents open to air flow?

Y

Height Inches Measurement 30 inches

Aesthetically PleasingNeed/Want Metric Test Target Value

Company Image - Survey Customer Review

Geometry - Survey Customer Review

Futuristic - Survey Customer Review

Material Selection - Survey Customer Review

Surface Finish - Survey Customer Review

Casters - Survey Customer Review

Low CostNeed/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

Easy to UseNeed/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)

Time Test, Survey ~ 30 seconds, Customer Review

Cable Management: Fiber Optic, Power, UPS, Foot Pedal

# of hanging cords, time to wrap (s)

Time Test, Survey 0, <30 seconds, Customer Review

Easy to UseNeed/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

SafetyNeed/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 (#)

- 0

Locking Wheels Number of Locking Wheels (#)

Count number of locking wheels

Minimum of 2

Preliminary Designs

Sponsor Feedback

Final Design

Final Prototype

Testing

Design Details

Mockup

Our Process

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

Caster SelectionStructure and Wheel Material

Single Wheel Caster

Twin Wheel Caster

Thermoplastic Polyurethane Polyolefin

Thermoplastic Elastomer

Caster SelectionFastening Type:

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

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

4th Iteration Design

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 ReviewResults:• Aesthetically appealing• Functional • Satisfactory cord and fiber

optic cable management

Survey Scale: 1 –Strongly Disagree , 2 –Disagree, 3 –Neither Disagree nor Agree, 4 –Agree, 5 –Strongly Agree

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.

Mechanical Testing: Tipping

Worst Case 4 – inch Casters 3 – inch Casters Current LiteCure CartSideways Tipping Angle

11 degrees 15 degrees 15 degrees

Stress Analysis

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 FeaturesFront 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 AnalysisQuote 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

User InstructionsAssembly• 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