1. Dhara Amin, Michael Brennan, Eric DiBlasi, Andrew Smith
Team LiteCure
Dhara Amin, Michael Brennan, Eric DiBlasi, Andrew Smith

2. Background
LiteCure: Manufacturing company for medical devices involving advanced laser technology for the health care and veterinary industries.
Products: Deep tissue therapy units that use laser technology to accelerate the body’s natural healing process.
Products are typically housed on a cart to allow the device to be transported from one patient to another in clinical settings

3. Motivation
LiteCure is in need of a custom cart design that solves several problems surrounding their current cart design.
Issues:
Poor fiber optic and power cord management
Lack of accessory storage and securing of those accessories
Aesthetic image of the cart
Ease of use and functionality improvements
Current LiteCure Cart

4. Project Scope Deliverables For Sponsor
To design an aesthetically pleasing utility cart for LiteCure’s deep tissue therapy unit that coincides with their desired image and allows users to easily access and store all components of the unit in a clinical setting.
Deliverables For Sponsor
Full Drawing Package of Final Concept
Manufacturing Details
Assembly Details
Prototype

5. Product Line
15 Watts watts
12 watts watts

6. Hand Piece and Fiber Optic Cord
Fiber Optic Cable:
3 meter length
Minimum bend radius of 3 inches

7. Product Accessories Patient Glasses Operator Glasses
Laser Head Attachments
“Doggles” (Veterinary Use)
UPS System
Foot Pedal (10 Watt Unit)

8. Benchmarking Cutting Edge K-Laser Anthro Cart UD PT Clinic Anthro Cart
Should replace Anthro design with the vet clinic cart
Cutting Edge K-Laser
Anthro Cart
UD PT Clinic
Anthro Cart
Vet Hospital

9. Design Requirements Compatible with product line
Aesthetically pleasing
Low cost
Easy to use
Safe

10. Product Compatibility
Need/Want
Metric
Test
Target Value
Support Weight of Laser Unit and all Accessories
Weight Capacity (lbs)
Failure Testing: Statics Calculation
>= 50 lbs
Accommodate each unit of product line
Platform dimensions (in)
Platform can accommodate largest unit (16.25 x 10.5 in)
>=16.25 x 10.5 in
Storage space for all accessories: (Safety Glasses, Head Attachments, Foot Pedal, UPS) -
Is there storage for all required accessories? Y
Stores Fiber Optic Cable
Is there storage for Fiber Optic Cable?
No blockage of Vents
Are all vents open to air flow?
Height
Inches
Measurement
30 inches
Potential questions: Why isn’t there an upper limit to the weight capacity?
We need to weight all accessories, also implement a safety factor.

11. Aesthetically Pleasing
Need/Want
Metric
Test
Target Value
Company Image -
Survey
Customer Review
Geometry
Futuristic
Material Selection
Surface Finish
Casters

12. Low Cost Need/Want Metric Test Target Value
Manufacturing Price Per Cart
Machining/Forming/Material Cost ($)
Quotes/cost calculations
$500-$700
Packaging
Shipping Weight (lbs)
Shipping Volume (in^3)
Packaging weight and volume calculations
35 to 50 lbs
< 3 ft^3
Number of Tools Required For Assembly
Number of Tools (#)
How many tools are required? 1
Where did we get a $100 for raw material cost?

13. Easy to Use Need/Want Metric Test Target Value
Quick and Easy Removal and Replacement of Fiber Optic cable
# of wraps, wrapping radius (in), time to wrap (s)
Time Test, Survey
5 wraps, >=3” wrapping radius, <30 seconds, Customer Review
Easily roll and transition over different floor mediums
Pulling Force (static and dynamic) (N)
Rolling Test
Passes Test (exceeds or meets current cart results)
Accessory Placement
Time to remove and store accessories (s)
~ 30 seconds, Customer Review
Cable Management: Fiber Optic, Power, UPS, Foot Pedal
# of hanging cords, time to wrap (s)
0, <30 seconds, Customer Review
Target values were obtained from testing the current LiteCure cart
Need to get actual metric for rolling test

14. Easy to Use Need/Want Metric Test Target Value Easy to Clean -
Can cart be cleaned with bleach, cleaning spray, or wipe? Y
Easy to Assemble
Time to assemble (mins)
5-15minutes
Ergonomics: Shelving
Survey: Are the shelves easily accessible and/or adjustable?
Customer Review
Target values were obtained from testing the current LiteCure cart

15. Safety Need/Want Metric Test Target Value Stability
Tipping Angle (Degree)
Tipping Test: At what angle does fully loaded cart tip?
10 degrees
Avoid Sharp Edges/Corners
Number of Sharp Edges (#) -
Locking Wheels
Number of Locking Wheels (#)
Count number of locking wheels
Minimum of 2
These metrics will be used to rank the team’s concepts except some tests cannot be performed until a prototype is made so we plan to make a few prototypes and rank them based on all the metrics.

16. Our Process Mockup Testing Preliminary Designs Final Design
Sponsor Feedback
Design Details
Final Prototype

17. Basic Component Design
Platform:
Where the units sit
Structure:
Body of the cart
Base:
Bottom of the cart: Where UPS sits
Caster Selection:
Caster size, type, and vendor
Accessory Design:
Compartments for: Fiber Optic Cable, Safety Glasses, Foot pedal, Head attachments

18. Structure Design

19. Structure Design

20. Platform Design

21. Base Design

22. Thermoplastic Elastomer
Caster Selection
Structure and Wheel Material
Single Wheel Caster
Thermoplastic Polyurethane Polyolefin
Thermoplastic Elastomer
Twin Wheel Caster

23. Caster Selection Fastening Type: Other Considerations:
Top Plate Threaded Stem Grip Ring Stem
Other Considerations:
Wheel Diameter: 3 or 4 inches
Locking Wheels: yes or no
Swivel: yes or no
Load Capacity: at least 50 lbs
Warranty: at least 2 years

24. Manufacturing Research
Anthro:
Materials used for shelving
Capabilities of a wood laminate design
Cart structure material
Minimal welds in design
Extreme Machining:
Press breaking capabilities
Tube bending practices
Water and laser cutting capabilities

25. 2nd Iteration Design

26. 3rd Iteration Design

27. 4th Iteration Design Chose C-shaped structure Added a locker
Incorporated the feel and lines of the LiteCure devices
Material: Carbon steel sheet metal

28. Mockup Material: Wood Casters: 4-inch and 3-inch Standard hardware
Mockup used for the following purposes:
Perform tipping and rolling test
Evaluate casters
Perform field test (in PT clinics)
Results:
Increase length and decrease width of platform
Front door design

29. Customer Review
Design: UD PT Clinic and LiteCure office used mock-up for three days and took survey.
Customer review measures:
Ease of Use
Aesthetics
Easy accessory placement
Easy shelf accessibility
Adequate storage
Easy to transport
Adequate cord management
Quick/Easy Wrapping and Removal of Fiber Optic Cable
Cord Management
Adequately display company logo
Futuristic feel
Appropriate Geometry
Appropriate material selection (sheet metal)
4-inch casters preferred

30. Customer Review Results: Aesthetically appealing Functional
Satisfactory cord and fiber optic cable management
Customer Review results for the questions asked about cord and fiber optic cable management. The mean values for the question are represented with correlating standard deviations.
Survey Scale: 1 –Strongly Disagree , 2 –Disagree, 3 –Neither Disagree nor Agree, 4 –Agree, 5 –Strongly Agree

31. Mechanical Testing: Tipping
Mention Standard (10 degrees) and measured tipping angle front, back, and side with load taken into consideration.
Worst Case
4 – inch Casters
3 – inch Casters
Current LiteCure Cart
Sideways Tipping Angle
11 degrees
15 degrees

32. Stress Analysis
Worst Case Scenario Bending of the platform and shelves point load in the middle
Pull out force for PEM Fasteners

33. Final Design Material: 14 Gauge & 16 Gauge Carbon Steel
Casters: 4 inch diameter
Fasteners: PEM fasteners
Features: Back locker, front door
Storage space: 1.9 ft^3
Height: 30 inches
Weight: 65 pounds

34. Final Design: Aesthetics
C – Shaped cart with curves and lines similar to LiteCure devices
Color scheme can be used for both product lines
Space for logo
Finish: Powder coated paints
Larger 4 inch casters

35. Final Design: Platform
One size platform for multiple devices
Refined dimensions
Perimeter around device
Hole for cord management

36. Final Design: Structure
Wide base for stability
PEM fasteners attach all parts
Flanges on shelves add strength
Converged to aesthetic design based on sponsor feedback

37. Final Design: Additional Features
Front Door:
Easy access to goggles and head attachments
Goggles stored in mesh bag on front door
Speed controlled hinge
Back locker
Easy access to all shelves
UPS and miscellaneous storage space
Rotating latch

38. Final Design: Additional Features
Fiber Optic Management
Hook design
Quickly drape cord over hook
Secure hand piece on device
Power Cord Management
Hole in top platform
Hole in back locker door
Internal guide for cords

39. Cost Analysis Quote of 1 Cart (machine shop) $1460
Does not include: PEM Fasteners, McMaster Hardware, Casters, Front Handle, and Fiber Optic Cable Management Hook.
Quote for 1000 number of units (machine shop)
$200 - $225 a unit
Hardware Cost: About $31 a unit
PEM Fastener Cost: About $30 a unit
Casters Cost: About $34 a unit
A thorough cost analysis could not be obtained because company is going to manufacture who has different pricing. But with this price everything but plastic parts are considered

40. User Instructions Assembly PEM fasteners press fit in to side panels
Detailed instructions for assembly
Only 1 tool needed: Wrench
Packaging
Cart can be broken down in to smaller, flat parts
Box dimensions: 27.5 in x in x 6 in

41. Design Validation

42. Path Forward Give LiteCure drawing package and assembly instructions.
LiteCure can take design to manufacturing company for start of mass production.
Small changes may need to be made to the design in order to be manufactured by a specific company.
More testing to sheet metal prototype: accelerated wear and overload testing