4D Products were approached by Rapid Rhythm when they needed a medical device design team to take an early stage concept for their rapid, handheld ECG device, and develop it to a point where 25 functional units could be produced for clinical trials.

A range of concept designs were presented, which explored form and function. Due to the nature of the device, and how it is used, ergonomic considerations for both patient and clinician were of high importance.

When a preferred concept had been identified, our 3D CAD designers translated it into fully detailed CAD models, ready for prototype and test. As it was envisaged the device would be manufactured in significant volume, we designed for the injection moulding process. Overmoulding was utilised in key areas to provide sealing, access to mechanical release buttons, and to add aesthetic appeal.

With a fully detailed 3D CAD model in place, we supplied CNC machined prototypes in full production materials and finishes. The whole product was then assembled and tested by the clients in house electronic engineering team.

Working with our supply chain, we supplied 25 sets of plastic parts (including overmoulding) using the vacuum casting process. This process delivers very high quality parts in an exact colour match, without the requirement to paint parts.