Engineering Office Munich
Product development of an EMS floor stand for medical technology
As part of the project, ID DESIGN developed a new floor stand for a medical EMS training device from miha bodytec. The goal was to integrate existing components such as the control unit, wireless unit, power supplies and cabling into a new, ergonomically optimized product architecture while consistently evolving miha bodytec's existing family design.
Key requirements included concealed cable routing inside the column, a control unit that can rotate through 180°, an integrated tray surface and high mechanical load capacity during EMS use and physical exercise.
ID DESIGN was responsible not only for concept development and industrial design, but for the complete mechanical product development – from analysis of the predecessor product through engineering, calculations and prototyping to series-ready CAD data, technical drawings and series-production planning.
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Concept Development, Ergonomics and Product Design
At the start of the project, ID DESIGN analyzed the existing floor stand as well as miha bodytec's complete product family. Ergonomic studies, wooden models and VR representations were used to define operating heights, reach zones, movement spaces and other ergonomic boundary conditions.
On this technical basis, different product design concepts were developed and evaluated in terms of aesthetics, function, manufacturability and integration into miha bodytec's existing design language.
Potential manufacturing processes and production costs were already considered during the design phase. Early cost estimates from potential series-production manufacturers made it possible to compare the various design variants not only aesthetically but also economically. The result was a product design that combines aesthetics, ergonomics, functionality and economical series production.
Mechanical development and
series-production-ready engineering
Already during preliminary engineering, ID DESIGN defined a suitable manufacturing process for each component and developed the geometries according to the respective production requirements. On this basis, a first functional prototype was created to evaluate ergonomics, operation, visual appearance and engineering weaknesses.
The findings from prototyping flowed directly into the further engineering work. At the same time, manufacturing and tooling costs were optimized. For example, originally planned manufacturing concepts were assessed for economic viability and components were redesigned for alternative processes such as injection molding where appropriate.
ID DESIGN then completed the detailed engineering of all components and created series-ready 3D CAD data and technical drawings. A range of manufacturing processes was used, including injection molding, aluminum extrusion, sheet-metal fabrication, welding, milling and deep drawing.
For the injection-molded parts, engineering considerations included demolding, wall thicknesses, ribbing, screw bosses, snap-fit connections, threaded inserts, surfaces, material selection and tolerance chains. DFM feedback from toolmakers and injection molding manufacturers was incorporated directly into the engineering.
Simulation, DFM and technical optimization
Already during preliminary engineering, ID DESIGN defined a suitable manufacturing process for each component and developed the geometries according to the respective production requirements. On this basis, a first functional prototype was created to evaluate ergonomics, operation, visual appearance and engineering weaknesses.
The findings from prototyping flowed directly into the further engineering work. At the same time, manufacturing and tooling costs were optimized. For example, originally planned manufacturing concepts were assessed for economic viability and components were redesigned for alternative processes such as injection molding where appropriate.
ID DESIGN then completed the detailed engineering of all components and created series-ready 3D CAD data and technical drawings. A range of manufacturing processes was used, including injection molding, aluminum extrusion, sheet-metal fabrication, welding, milling and deep drawing.
For the injection-molded parts, engineering considerations included demolding, wall thicknesses, ribbing, screw bosses, snap-fit connections, threaded inserts, surfaces, material selection and tolerance chains. DFM feedback from toolmakers and injection molding manufacturers was incorporated directly into the engineering.
Industrialization and preparation for series production
ID DESIGN supported the project beyond the engineering phase through to its transfer into series production. Together with the respective manufacturers, all components were optimized with regard to Design for Manufacturing (DFM), tooling, manufacturing, assembly, quality and cost.
After completion of the engineering work, the final CAD data and technical drawings were transferred to the selected manufacturing partners. Using the first T0 injection-molded parts from the production tools, a near-series overall prototype was assembled and systematically analyzed.
Identified optimization opportunities were evaluated together with the injection molders and other component manufacturers and incorporated into the design in a manufacturing-compatible manner. The resulting T1 samples were used to verify the changes again and further validate readiness for series production.
ID DESIGN's scope therefore covered the entire mechanical product development process: product design, mechanical engineering, technical drawings, prototyping, simulation, DFM, supplier coordination, and the technical preparation and support of series production.
