Concept to Production Medical Device
A local doctor had an idea for a revolutionary way to treat wounds. Trials on animals proved his idea works, now it was time to try clinical trials on humans. But first he needed a mechanical design that would work on humans. Because it was in contact with the patient, the material needed to be medically inert. It also needed to be pliable, waterproof, and transparent with injection ports for an IV set. Shipman listened to his needs and designed a custom liquid injection molded part made of medical grade silicone. The mold was machined in-house and a first prototype produced in days. In less than 8 weeks Shipman took the project from an idea into production parts that are being used in the clinical trials on humans.
Robotic Assembly
A client came to us with a check valve assembly that was very costly for them to implement. Additional machining steps were needed to overcome the limited bonding capability of the incompatible materials that made up the assembly. Quality problems plagued the end product, a Class 1 medical device, greatly reducing production yield and increasing problems for the quality department.
Shipman reviewed the current design and proposed three different alternatives for the client. The best option was chosen, and an automated work cell using SCARA robots was designed, built, and deployed at Shipman Technologies. Currently, the robots produce over 1 million check valves a year. And while we’ve significantly reduced the cost for our client, we’re most proud of the fact that there has never been a single field failure of the new valve design.
Leak Problem Solved
The chicken hatchery is one of the harshest environments for sensitive electronics. Bio-hazardous waste, constant cleaning with water and harsh chemicals, and temperature extremes are just some of the challenges that call for unique solutions to packaging and assembly. Our client houses their electronics in a custom machined ABS enclosure sealed with a conventional Viton O-ring. The O-ring was a constant source of leaks, resulting in callbacks for field service to replace faulty units and destroying thousands of dollars in expensive electronic assemblies. The irregular profile of the enclosure meant replacement O-rings had to be made in the field by the service people, requiring them to carry extra tools and materials.
Shipman Technologies engineered new die-cut silicone gaskets to replace the unreliable O-ring. Custom dies ensure the new gaskets fit exactly on the existing enclosure, ensuring a perfect seal every time and eliminating the field problems associated with old O-ring. The Shipman gasket, unlike the O-ring, is impossible to misalign. Custom packaging of the gaskets makes it easy for the customer to stock and inventory the gaskets, ensuring they arrive in field in perfect condition for installation.
Case Studies