Collaborating on Prototype Refinement

The Challenge

In partnership with Karten Design, a product design and innovation consultancy, Minnetronix was charged with designing and producing a working prototype that looked and functioned like a finished device for a wearable acoustic emission monitoring product that assessed orthopedic joint health. The project included internal and external design of the full device, a rolling console, as well as a redesign of the wearable sensor.

The original wearable sensor components could be carried in a pack. Image courtesy of Minnetronix.

The client had already engaged with Karten Design and was seeking a partner with electromechanical expertise and extensive experience in the medical device industry who could collaborate effectively with Karten. Minnetronix and Karten were asked to deliver a near-commercial prototype in less than six months so that it could be demonstrated at a major tradeshow.

The Solution

Karten Design led the human factors, usability and industrial design of the rolling console. They designed the look and feel of the device, developed a user interface design concept and developed the outer housing. The intent was to create a system that would add value to a physician’s practice while eliminating any barriers to learning a new device.

Meanwhile, Minnetronix, leveraging their deep domain expertise in electromechanical engineering, focused on the inner workings of the rolling console. They developed the single board computer, software, custom electronics and custom display with a touchscreen. Additionally, Minnetronix managed the system integration and data acquisition and implemented the Karten-designed custom user interface for the rolling console.

The collected data on the rolling console was designed to aggregate data in real time. Image courtesy of Minnetronix.

In addition to the work on the rolling console, Minnetronix and Karten Design redesigned the wearable sensor. The original wearable sensor component was the size of a large fanny pack and weighed nearly 2 lbs. It contained a battery, Wi-Fi device, Bluetooth for motion sensors and a single board computer to gather sensor data. The data was collected in the wearable sensor and then was transferred to the laptop computer through a series of manual steps.

Utilizing their respective expertise, Minnetronix and Karten Design developed a wearable acoustic emissions sensor that was smaller than a standard computer mouse and required only a USB connection for power. The analog filter and FPGA (field programming gate array) in the acoustic emissions sensor detected smaller signals, generated less background noise, and had a higher event rate than the original system. Additionally, the new sensor collected and transferred real-time data electronically rather than via a series of manual steps. The data transfer rate on the new sensor was three times better than the original accelerometer. Minnetronix was also able to reduce the cost of production of the acoustic emissions sensor by sourcing lower-cost components.

With the redesign, Karten Design and Minnetronix created a new wearable sensor about the size of a computer mouse. Image courtesy of Karten Design.

Design & Engineering

• Relied on Minnetronix’ comprehensive knowledge to develop a single board computer and remote sensor, software, custom board and custom display with touchscreen.
• Leveraged Minnetronix’ electromechanical expertise to implement the Karten-designed custom user interface for the rolling console.
• Coordinated electronics design with Karten Design’s industrial design effort to ensure the inner workings of the device fit into the final industrial design for the outer casing of the rolling console.

Quality Assurance

• Utilized Vital Link and Minnetronix Quality Systems to assist in meeting a tight timeline and ensure project efficiency and alignment.

The Result

Utilizing constant communication and tools such as Vital Link, Minnetronix’ proprietary customer portal, Minnetronix and Karten Design worked together to maintain the project schedule, action list and ensure timing was on track. The result was the development of a highly functional device and wearable component in less than six months. By meeting the tight timeline, the client was able to demonstrate the device and wearable prototype at a major tradeshow allowing the client to gather customer feedback and move toward commercialization.

More Info:

• Karten Design
• Minnetronix