Product re-engineer and design optimisation
For an advanced medical device manufacturer
Challenge
The client’s initial product was costly and complex to manufacture, which limited its supply and accessibility. The use of a multi-board architecture with FPGAs contributed to this complexity and inefficiency.
Additionally, the need for rapid, high-volume data transfer and image processing highlighted the requirement for an optimised system architecture to enhance performance and usability.
Solution
The solution involved designing a modular architecture that replaced the multiple FPGA boards with a single-board computer (SBC), a carrier board, and a Texas Instruments TMS320 Digital Signal Processor (DSP) for efficient image capture and processing.
A custom PCIe card was developed, incorporating high-speed analogue-to-digital converters (ADCs) and optimized firmware to ensure seamless data transfer to the DSP.
Additionally, comprehensive design files, firmware, and documentation were provided for a production-ready solution that met both quality and regulatory standards.
Learnings
The project provided several valuable insights, such as the realization that simplified, single-board architectures can substantially lower costs while maintaining high performance.
It also highlighted that DSP-based designs effectively optimise fast image capture and data handling, offering a reliable solution for high-throughput medical devices.
Furthermore, bringing in Consult Red as an external consultant enhanced decision-making and improved timelines while fostering greater accountability within the client’s engineering team.
Impact and Value
The impact and value of this project were significant, as streamlined manufacturing and reduced costs facilitated scalability, enabling the client to meet demand more effectively.
It empowered the client’s engineering team with a robust, scalable design, allowing them to concentrate more on innovation.
Additionally, the project delivered a complete solution that included full design, documentation, and prototypes, significantly accelerating the client’s time-to-market.
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