Addressing obsolete medical testing equipment
Our client, a leading manufacturer of oncology treatment equipment, approached us with a critical challenge! They currently produce a wide range of medical devices, including a treatment couch used during radiotherapy and scanning procedures. This motorised, fully automatic couch is essential for precise patient positioning and must undergo rigorous testing before deployment into hospitals.
The original test equipment used during the assembly and quality control process had become obsolete, as its manufacturer no longer existed, a problem many manufacturing facilities encounter. Our task was to redesign and manufacture a modernised test system that would ensure the continued high performance and reliability of these important oncology treatment couches.
Overcoming medical legacy design constraints
- The original test system was no longer in production
- The available technical drawings were outdated and created using a legacy CAD system
- The new testing system had to seamlessly integrate with the existing oncology treatment couches and meet stringent medical equipment standards
- A secondary test system was needed to assess the functionality of large mechanical turntables that transported patients between scanning and treatment machines
What did this project involve?
- Reverse Engineering of old drawings and schematics
- Design of bespoke circuit boards and control boards
- Design of a bespoke control pendant to remotely control the system
- Sourcing of hard to find/obsolete components
- Electronics Rack wiring
- CNC panel machining and engraving
- System installation and commissioning
Engineering a modern medical testing solution
Reverse engineering & CAD modernisation
We began by conducting a comprehensive audit of the existing documentation and equipment. Although original CAD drawings were available, they were outdated and required a full digital transformation. Our team meticulously converted these old files into a modern CAD format, refining and updating the design for manufacturability and longevity.
Developing an oncology test system
The testing system was composed of two key components:
Main Interface Unit: This unit connected directly to the couch’s electronics, controlling its movement and verifying proper function
- Handheld Controller: Used by operators during assembly, this controller enabled real-time testing of the couch’s various motorised movements, ensuring all functions met strict quality standards
Expansion to oncology turntable testing system
Following the success of the initial test system, the client commissioned us to design a secondary system to test their mechanical turntables. These turntables allow the treatment couch to move seamlessly between different scanning and radiotherapy machines without disturbing the patient.
This secondary test system had to:
Automate the movement of the turntables to verify smooth, unrestricted motion
Detect mechanical resistance or rough patches during operation
Monitor and validate positional encoders for accuracy
Log all test data and display it on a graphical LCD screen for real-time analysis
Custom electronics & software development for medical testing
Unlike the couch test system, the turntable test unit had no pre-existing design. We developed the electronics from scratch, designing and manufacturing a fully functional test interface. Our engineers also wrote the custom software that controlled and monitored the test process, ensuring compliance with the client’s quality assurance protocols.
Ensuring long-term medical equipment reliability
Seamless production continuity: Our new test systems ensured that the client could continue manufacturing and testing their oncology treatment couches without disruption
Enhanced testing accuracy: The new systems provided more precise data logging and improved reliability in quality control processes
Long-term reliability: With up-to-date CAD designs and scalable electronics, the client now has a future-proof solution for their testing needs!
Client satisfaction: The project’s success led to an expanded partnership, with our team developing additional testing solutions for the client’s broader range of medical equipment
Future-proofing oncology equipment testing
This case study highlights our expertise in modernising legacy testing systems for critical medical equipment. By combining advanced CAD design, custom electronics engineering, and tailored software solutions, we successfully delivered a future-ready testing platform for oncology treatment devices. If your business faces similar challenges with outdated test systems, we can help you design and implement cutting-edge solutions to ensure reliability and compliance.
