Key Takeaways
Root cause of failures identified in all three prototype units
Battery cover redesigned
Display component redesigned to clear the disc
Three demonstration devices built with high-tolerance printed and painted parts
Investor-ready prototype delivered with recommendations for high-volume production
Quick Answer
A healthcare startup had launched an early version of its portable creatinine measuring device, and customer feedback pointed to mechanical problems that were hurting confidence in the product. The startup needed a stronger prototype to raise more funds and a design that could move toward high-volume production. Goken reviewed the design documentation and the earlier failure analysis, found the root cause of failures in three prototype units, and upgraded the battery cover and the display component that collided with the disc. Goken also built three demonstration devices with high-tolerance printed parts and a painted finish.
Context
Creatinine is a marker that doctors use to check kidney function. The startup had built a portable device to measure it and had put an early version in the hands of customers. The device worked. It also showed weaknesses once people used it outside the lab.
Challenge
Three prototype units had three different problems: one unit failed outright, one had mechanical failures, and one had a single electrical connection that was never made
The display component collided with the disc
The battery cover design needed an upgrade
The device had been built to prove the concept, so the earlier failure analysis and assembly documentation had to be reviewed before any change could be trusted
Approach
Documentation and failure review: The team studied the mechanical design, the assembly steps, and the earlier root cause analysis before touching any hardware
Root cause debugging with the electronics consultant: Each failing unit was debugged together with the electronics consultant of the client, so every failure was traced to the right cause
Component redesign: The battery cover and the display component were redesigned, and the display component now clears the disc
Prototype build for demonstration: Parts for three devices were 3D-printed to high mechanical tolerance and surface finish, then painted for an aesthetic look
Robustness recommendations: The team suggested improvements for the mechanical longevity and robustness of the design, and supported the alpha prototype as new issues came up
Results
Area | Outcome |
Failing prototype units | Root cause identified for all three |
Battery cover | Redesigned |
Display component | Redesigned to clear the disc |
Demonstration devices | 3 built with printed, painted parts |
Prototype status | Delivered as an investor-ready prototype |
The startup now has demonstration units and design recommendations for the move toward high-volume production.
What This Reveals
A prototype only needs to survive a demo. A shipped device has to survive daily handling by people who did not build it. Most of that stress lands on covers, connections, and the fit between parts, long before anyone questions the sensor or the software. Finding the true cause of each failure and fixing it at the point where it occurs is usually the fastest route to a product that an investor and a factory can both stand behind.
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