Background
In the realm of medical devices, precision is paramount. So, when a startup approached us with a groundbreaking endoscope application designed to aid doctors in locating polyps in the colon, we knew the stakes were high. Their product, a crucial tool in early cancer detection, hinged on the reliability of its components. However, their initial attempts hit a roadblock: parts sourced were failing after just a few bends.
The Challenge
The challenge lay in the intricate design of the endoscope’s neck. With the camera end requiring frequent bending and unbending to extreme angles during procedures, the strain on the components was immense. The existing 4-layer design, which had suboptimal stackup and routing, led to excessive stress, causing traces to crack and components to detach—a devastating setback for our client’s aspirations.
Identifying Critical Design Flaw
Recognizing the urgency of the situation, our team sprang into action. We met with the client to assess the issues firsthand and formulate a solution. Collaboratively, we identified weak points in the design, pinpointing areas where traces were breaking, and selecting the materials, stackup, and routing adjustments that were needed. Drawing on our expertise in material science and design engineering, we proposed a comprehensive overhaul, addressing every aspect from stackup configuration to component placement.
Our approach was diligent
We reconfigured the stackup to introduce layers specifically dedicated to the bend regions, minimizing thickness and stress concentration during flexing. We strategically staggered the traces in these critical areas, reducing the risk of cracking. We optimized component orientation, ensuring that solder joints were perpendicular to the bend, enhancing durability. We recommended carefully selected material grades and thicknesses to further strengthen the endoscope’s resilience to dynamic flexing.
Results
With our design improvements, the endoscope modules successfully performed as expected. Under strenuous stress tests, all traces remained intact, and all components remained in place. Our client successfully brought their product to market, achieving their goal of aiding in early cancer detection. What began as a manufacturing setback evolved into a triumph of innovation and collaboration.
Our success didn’t go unnoticed
Impressed by our dedication and expertise, the VP of Operations brought us onboard his new venture—a company focused on developing devices for breast reconstruction. Once again, our team rose to the challenge, leveraging our skills to propel another groundbreaking medical innovation to success. Through our commitment to excellence, we not only helped our clients realize their visions but also created long-lasting partnerships built on trust and results.