Project Summary

Product: GastroCH4ECK® Gastrolyzer®

Services: Product Redesign, Design for Manufacture (DFM), Prototyping, Assembly Engineering

Requirement: Integrate new laser analysis technology within the existing GastroCH4ECK Gastrolyzer platform whilst retaining the established product footprint, improving assembly and servicing, and creating a platform for future product development.

Outcome: A modular redesign integrating next-generation laser analysis technology while improving manufacturability, simplifying servicing and creating a scalable platform for future product development without changing the product’s familiar footprint or user experience.

Project Benefits

  • Existing product footprint retained.
  • Integrated next-generation laser analysis technology.
  • Introduced a modular product architecture.
  • Simplified assembly and production testing.
  • Improved access for servicing and maintenance.
  • Optimised use of the available internal space.
  • Simplified stock control through modular sub-assemblies.
  • Created a scalable platform for future product development.

Background

Bedfont Scientific wanted to modernise its established GastroCH4ECK Gastrolyzer by integrating next-generation laser analysis technology, updated processing equipment and a modern user interface, whilst retaining the product’s established footprint and external connectivity layout.

The GastroCH4ECK Gastrolyzer had earned a strong reputation within clinical environments, with healthcare professionals familiar with its form factor, connection locations and day-to-day operation. Any redesign therefore needed to preserve the established user experience whilst accommodating significant changes to the internal architecture.

Alongside the technology upgrade, Bedfont wanted to improve assembly, simplify servicing and create a product that would be easier to manufacture and support throughout its operational life. Achieving these objectives required careful integration of the new technology whilst maintaining the product’s performance, usability and long-term reliability, without compromising its established user experience.

 

Requirement

A key objective was to integrate a new laser analysis bench within the existing GastroCH4ECK Gastrolyzer platform without changing the product’s established footprint or external connectivity layout.

This created a number of engineering challenges. Strict limitations on available height, combined with the physical constraints of the laser bench wiring loom, left very little flexibility in how components could be arranged internally. With available space at a premium, changes in one area of the design often had implications elsewhere, requiring careful consideration of component packaging, accessibility and assembly throughout the product.

The redesigned product also needed to:

  • Accommodate the new laser analysis technology.
  • Retain the existing footprint and external connectivity layout.
  • Improve access for servicing and maintenance.
  • Simplify assembly and production testing.
  • Support future product development and technology upgrades.

Solution 

Working closely with Bedfont’s engineering team, DTI redesigned the GastroCH4ECK Gastrolyzer around a modular architecture that improved manufacturability and serviceability whilst creating a flexible platform for future product development

A modular approach was adopted, dividing the unit into a number of sub-assemblies that could be built and tested independently before final assembly. This simplified the build process, improved access to key components during servicing and maintenance, and created a more efficient manufacturing process through independently validated assemblies.

The enclosure was redesigned using aluminium sheet metal construction, providing the strength, low weight and dimensional stability required for the application. A high-performance architectural powder-coated finish was specified to meet the product’s high cosmetic and durability requirements, with precision-machined plastic and stainless steel components retained where durability and accuracy were critical to maintaining functional performance.

Throughout development, prototype parts and assemblies were produced to assess fit, service access and integration of the laser analysis bench. Design refinements were made throughout the project to ensure the final product could be manufactured consistently and supported effectively in service.

Outcome

The redesigned GastroCH4ECK Gastrolyzer successfully integrated next-generation laser analysis technology without changing the product’s established footprint, external connectivity or familiar user experience. This enabled Bedfont to introduce new technology while maintaining continuity for existing users and clinical environments already familiar with the product.

The modular architecture simplified assembly and production testing, improved access to key components for servicing and maintenance, and made more effective use of the available internal space. This reduced manufacturing complexity, streamlined assembly and created a product that was easier to build, support and maintain throughout its operational life.

By redesigning the platform with future development in mind, Bedfont gained a more flexible product architecture capable of accommodating future technology upgrades without the need for a complete redesign. The result was a modernised medical device that not only met the immediate project objectives but also provided a scalable platform for long-term product evolution.

 

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