Project Summary

Industry: Medical & Healthcare

Services: Electronic Product Development, PCB Design, Mechanical Design, Ergonomic Design, Injection Mould Tooling, Assembly Engineering, Manufacturing

Requirement: Develop an ergonomic, waterproof hand controller and integrated monitoring system that would improve the user experience while providing accurate equipment usage data to support maintenance planning and long-term product management.

Outcome: A fully integrated control and monitoring solution that improved usability, gave the client greater visibility of product usage and created a scalable platform for long-term manufacture and future product development.

Background

A leading manufacturer of assisted bathing equipment approached DTI to develop a fully integrated control and monitoring solution for its bath lifter platform.

Used in hospitals, care homes and other healthcare environments, assisted bathing equipment must be reliable, intuitive to operate and capable of withstanding frequent cleaning and regular exposure to water.

The client also wanted greater visibility of how its products were being used once deployed, enabling maintenance planning, battery replacement scheduling and long-term product management to be based on actual equipment usage.

The challenge was to introduce these additional capabilities without redesigning the existing bath lifter drive system or changing the familiar user experience.

Requirement

The project required two complementary products engineered to operate as a single integrated system.

The hand controller needed to be comfortable and intuitive for users with limited dexterity, while remaining robust enough to withstand everyday use in demanding healthcare environments.

The monitoring unit needed to distinguish genuine operating cycles from background electrical signals while consuming minimal power, ensuring accurate usage data could be collected without affecting battery performance or interrupting normal equipment operation.

The solution also needed to:

  • Achieve IP67 environmental protection.
  • Remain compact and tamper resistant.
  • Integrate with existing installed equipment as well as future product variants.
  • Support repeatable manufacture and long-term production.

Solution

Working closely with the client’s engineering team, DTI delivered a complete design-for-manufacture solution covering the electronic, mechanical and manufacturing development of both products.

The hand controller was engineered with ergonomics, accessibility and durability as key priorities. Tactile raised controls, clear operating graphics and a secure anti-slip grip created a product that was comfortable and intuitive to use, particularly for users with limited dexterity.

Custom electronics, sealed cable assemblies and waterproof connector systems enabled reliable long-term performance in demanding healthcare environments while achieving full IP67 protection against water ingress.

In parallel, DTI developed a compact in-line monitoring module that integrated seamlessly with the existing bath lifter platform. A bespoke PCB was engineered to accurately distinguish genuine operating cycles from background electrical signals, ensuring reliable operating data could be captured without increasing power consumption or affecting normal equipment performance.

The modular architecture enabled the monitoring system to be integrated into both new production units and existing installed equipment without redesigning the main bath lifter platform. This protected the client’s existing product architecture while creating a flexible foundation for future product development.

Mechanical and electronic development progressed together throughout the project to ensure both products operated as a single integrated system. Prototype assemblies underwent extensive functional, immersion and lifecycle testing to validate ergonomics, waterproofing, electrical performance and manufacturability before production tooling, assembly processes and quality controls were established for reliable volume manufacture.

Outcome

The completed solution gave the client far greater visibility of how its products were being used once deployed in healthcare environments.

Rather than relying on estimated usage or fixed service intervals, maintenance planning could now be supported by actual operating data. This enables more informed preventative maintenance, battery replacement scheduling and long-term lifecycle management, helping healthcare providers maintain equipment more effectively while maximising availability.

Having designed the monitoring system to be compatible with both new production units and equipment already installed in the field, these additional capabilities could be introduced across the product range without redesigning an established platform. This protected the client’s existing investment while simplifying the introduction of enhanced functionality.

The ergonomic hand controller also improved the day-to-day user experience, providing reliable, intuitive operation in demanding clinical environments while maintaining the durability and environmental protection required for long-term service.

Together, the control and monitoring system provides the client with a commercially manufacturable solution that not only improves product usability but also delivers valuable operational insight. The result is a scalable platform that supports ongoing product development, long-term manufacture and better-informed product management throughout the equipment lifecycle.

Get in touch today to discuss your next project

Whether you have a question, require more information, or want to discuss a potential project, our expert engineering and operations teams are on hand to help you.

We look forward to hearing from you and collaborating on innovative solutions for your business.

"*" indicates required fields