The project
As device development progressed, the client required a flexible and low-risk method of assembling units while continuing to iterate the design. The equipment needed to:
- Build devices for clinical trial supply
- Support functional testing and design iteration
- Evaluate and de-risk assembly processes ahead of commercial line development
Rather than a single machine, we broke the complete assembly process down into defined stages and developed eight individual benchtop units, each tailored to a specific step. In addition, we worked closely with a specialist 3rd party vendor to specify, procure and integrate four ultrasonic welding units into the benchtop equipment suite line.
In many ways, the design process mirrors the approach of a watchmaker. Just as the precise machining and careful arrangement of gears ensures a mechanical watch functions flawlessly without electronic correction, these fixtures rely on carefully engineered geometry and tolerance control to guide each component into its correct position. The result is a highly repeatable assembly process built on mechanical precision rather than operator judgment.
A structured approach to de-risking scale-up
This project was approached as an enabling step towards automation. The purpose of the fixtures extended beyond manual assembly; they were designed to generate process understanding, validate tolerances and inform the architecture of the future commercial production line. By investing in structured development equipment early, the client can progress confidently towards market entry with significantly reduced technical and operational risk.
