Multi-Technology Ultrasound Control Panel

Challenge:
Size and complexity of cosmetic housing. Video interface over a long distance. Multiple controls integrated within same console along with requirement to be user friendly in both bright and low light environment.

Solution:
Gas assist injection molding. Custom integrated PCI card along with corresponding interface card within console and full integration with a variety of controls; keyboard, encoders, slide potentiometers, and rotary encoders with backlighting throughout.

Application:
Medical ultrasound device

Innovations:
Packaging and interfacing of multiple technologies were merged so that the assembly could integrate a trackball, slider pots, QWERTY, backlit plastic keys, plastic molding, probe holders, multiple electronic technologies and more.  Provide uniform backlighting throughout the console.

Control Device

Challenge:
This device had to be sealed and washable with backlighting and re-configurable legends.

Solution:

• Elastomer layer extends around perimeter, assuring full seal.
• Low profile overlay and embossed keys minimize collection of debris.
• Washable elastomer overlay.
• Overlays shipped separately from keyboard, allowing custom configuration on site.
• Backlighting achieved via right angle LED's arrayed around keys, using translucent elastomer to diffuse the light.

Application:
Medical environment

Innovations:
Backlighting solution

Controller for x and y Axis of X-ray Table

Challenge:
This complex device required the incorporation of multiple switch technologies with tight precision on switch control.

Solution:
Incorporated several precision machined parts such as knobs and joysticks to accommodate exact movement of x-ray table.

Application:
Medical in-room controller for x and y axis of x-ray table.

Innovations:
Multiple technologies with precision fit. Illuminated overlay.

Veterinary Diagnostic Equipment

Challenge:
The display needed to be packaged in a stand alone unit that matched the “look” of the other pieces of equipment and that could function at distances over 10 feet from the PC.

Solution:

• A combination of a custom PCI card in the PC and a subsequent custom Receiver card in the display was necessary to provide the ability to drive video at an extended distance.
• Aesthetics were handled with custom plastic skins incorporating a sophisticated structural design.

Application:
Sole control device for a system of diagnostic equipment used in Veterinary offices.

Innovations:
Driving video over a significant distance, maintaining rigidity with a cantilevered display.

Challenge:   Develop a flush dual stage button system in bent steel tubes to include a safety circuit.  To develop frame assembly with bent tubes that can move a >500 lb system but weigh near 15 lbs.
 
Technology: Display/Touch Screen assembly with dual stage elastomer switches.
 
Solution:  Dual Elastomers switch with a membrane circuit that is thin enough to fit inside the tube and be used inside the plastic housing.  Strategically lighten the interior frame and tube to decrease weight without losing strength or to allow unacceptable emissions.
 
Innovation: Switches and wire harness must fit inside tubes during assembly.

Challenge:  Re-design an existing FDA approved product to improve the performance  of  the joystick assembly and reduce   overall   cost, without  changing  any cosmetics,  look or feel of the controls. 
  
Technology:  Mid-travel plastic key over mechanical switch. 
  
Solution:  Changed the design of the joystick from high tolerance machined parts to a combination of high tolerance injection molded parts and stamped metal parts.  Converted electronic design from a complex multi-use circuit assembly to a solution tailored to this specific product. 
  
Innovation:  Increased analog joystick life more than 10 times. Decreased part count and complexity of electrical assembly.

Technology: Flat Panel, tactile dome keypad
 
Challenge:  Provide a custom, low cost keypad with a multi colored embossed overlay and embedded LEDs for lightweight portable medical device.
 
Solution:  Snap domes over a flex membrane. Five color overlay. Two embedded LEDs.
 
Application: Medical

Application:  Marine/Surveillance and Rescue 
 
Challenge:  A control panel to be used on Marine vessels to operate an Infrared camera system.  The unit must have six pushbuttons, a multi-axis joystick, and a character display.  An LCD display module with one row of 16 characters and red LED backlight is required. The pushbuttons must actuate tactile dome switches. The buttons must be backlit with red LEDs and must meet Marine specification IEC 60529 and IEC60945.  
 
Solution: The JCU, which utilizes Ethernet technology to communicate with the host and cameras. Power is supplied over the Ethernet connection

Co-molding is a relatively new process which is gaining popularity and has become one of the industry's fastest growing molding technologies. It is being driven by marketing teams, end users and customers who are all looking for new ideas and leading edge ideas for consumer goods.  This technology produces products which have a "soft touch" and "tactile feel".

The process to manufacture a silicone co-molded bezel utilizes two types of molds and a complex manufacturing procedure.  The end result is a rigid part, covered with a soft feeling, tactile layer of silicone material. Typically, after the part is molded, it is decorated by painting the surface and adding silk-screened and/or laser etched graphics.  A protective top coat is often applied to the cosmetic surface.

Co-molded technology has been incorporated in a wide range of products varying from medical and military equipment to cell phones and baby toys.