Designed Mobile Hotspot With Multi-device Connectivity

Overview

A global leader in a range of medical devices like portable defibrillators and ventilators used by clinicians and emergency medical services to treat victims in times of resuscitation and acute critical care.

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Challenges

The client wanted to design its in-house Mi-Fi module that relays data on LTE over Wi-Fi and provides data connectivity with guaranteed throughput and quality of service for global geography

Solution

Mechanical Design and Prototyping of Modem Device
- Designed conceptualization sketches with three different options
- IP-55 enclosure design
- 3D CAD design and 2D detail drawing
- Product level thermal analysis & CFD simulation
- Simulations: shock, drop, bump and vibrations
- 3D prototyping in DFM and SLA for form factor validation and field testing
- Mold tooling – 300K+ production capacity
- Reliability testing as per RTCA/DO-160G
  - Bump and shock testing
  - Sine and broadband vibration testing
  - Altitude testing
  - Humidity and temperature testing
  - Drop testing
  - IP-55 testing
- Silk screen printing process for IO port and LEDs
- Translucent light pipe for LED indication
- Blue color enclosure with Grey buttons and white strips
- No shrink or gate mark visible at single places
- Defining cosmetic inspection criteria to make sure 0% rejection on product final assembly line
- Mass manufacturing >5K units
- Mold maintenance
Hardware design with end-of-life analysis, memory, and power budget analysis with 5 GHz radio
Design component analysis and testing for antenna diversity, thermal analysis, signal quality testing, fuel gauge calibration
FCC, CE, IC, PTCRB, Verizon, AT&T certification

Outcomes

Delivered mechanical and electronic hardware to fit in the available size and weight. Improved time and quality of medical service by sending real-time patient data from connected medical devices over Wi-Fi & LTE for analysis and monitoring by the hospitals while on the way
Delivered product compliant to Reliability standards for Medical Devices, also supports FirstNet for use in Emergency Medical Services (EMS), provides Wi-Fi 11ac/b/g/n & LTE Cat 4 connectivity
Mobile Hotspot enabled with multi-device connectivity to serve multiple medical equipment simultaneously in case of emergency